Schwing Sp 500 English

Line Pump Division5900 Centerville RdWhite Bear, MN. 551271-888-SCHWING (724-9464)www.schwing.com

OPERATION MANUAL FOR CONCRETE LINE PUMPS

All SP “Rock Valve” Models

Part Number 30100750

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

Revision date 01/10

Version2.0.1

OPERATION MANUAL FOR

ALL SP ÒROCK VALVE ” MODELS

Part Number 30100750

Version 2.0.1

Copyright © 2010, SchwingAll rights reserved

swg99a001.eps

Table of Contents

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Introduction

Manufacturer’s Statement......................................................................... 10Safety alert symbol and signal word explanation ............................... 10How to reach us .................................................................................. 11How to order parts .............................................................................. 11

Model Number:......................................................................................... 11Serial Number: .......................................................................................... 11ID Tag Location........................................................................................ 12ID Tag ....................................................................................................... 13

If your ID tag is missing ..................................................................... 13

Specifications

Concrete Pump Specifications .................................................................. 16Hydraulic Pressure Specifications ............................................................ 19

Safety

How to Order Additional Safety Manuals ................................................ 22

Product Overview

First Commissioning................................................................................. 26Installation of your new unit ............................................................... 26

Machine Description................................................................................. 27Emergency Stop switches ................................................................... 27Concrete pump hydraulic pumps ........................................................ 28Concrete Pump Circuit........................................................................ 28

BPA Circuit Diagrams .............................................................................. 32Phase A ............................................................................................... 32

Phase B ..................................................................................................... 34Phase C ..................................................................................................... 36Phase D ..................................................................................................... 38Phase E...................................................................................................... 40WP Circuit Diagram ................................................................................. 42

Phase A ............................................................................................... 42Phase B ..................................................................................................... 44Phase C ..................................................................................................... 46Phase D ..................................................................................................... 48BPA 2000 Circuit Diagram....................................................................... 50

Phase A ............................................................................................... 50Phase B ..................................................................................................... 52Phase C ..................................................................................................... 54Phase D ..................................................................................................... 56Phase E...................................................................................................... 58Phase F...................................................................................................... 60Phase G ..................................................................................................... 62Phase H ..................................................................................................... 64

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Operation Manual - v

Phase I....................................................................................................... 66Phase J....................................................................................................... 68Phase K ..................................................................................................... 70Component Locations ............................................................................... 72

Right Side Components ...................................................................... 72Towing End......................................................................................... 76Left Side.............................................................................................. 79Hopper Area........................................................................................ 87

Safety Devices .......................................................................................... 90Emergency Stop Switches................................................................... 90Automatic Shut-off Circuit Agitator................................................... 90Safety Valves (Pressure relief valves) ................................................ 90Safety Guards...................................................................................... 90Fuses ................................................................................................... 90Warning Labels................................................................................... 91

Operation

Preparation ................................................................................................ 98Arrive to work on time, with a clear head. ......................................... 98Have the right machine for the job. .................................................... 98Have the equipment that you will need for the job............................. 98Have the right personal protective equipment for the job................. 100Check the equipment before leaving the yard................................... 101

Towing the unit ....................................................................................... 102Licensing........................................................................................... 102Backing up. ....................................................................................... 102Changing lanes.................................................................................. 102Loading the unit for shipment........................................................... 102

Unit Set-Up ............................................................................................. 103Selecting the proper set up location on the job site. ......................... 103Laying out the pipeline ..................................................................... 103Setting the Stabilizers ....................................................................... 103

Operating the Pump ................................................................................ 104Basic Troubleshooting ...................................................................... 104Before the first truck backs up to your hopper ................................. 104Lubricate your pipeline. .................................................................... 108To control the speed of the unit ........................................................ 110Pump the job ..................................................................................... 111Time Constraints............................................................................... 112To disable the entire unit in an emergency ....................................... 113Delays ............................................................................................... 113Keep the waterbox full...................................................................... 113Use of the vibrator ............................................................................ 113Blockages.......................................................................................... 114Clean-out........................................................................................... 114Clean the hopper ............................................................................... 115

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Clean the rock valve and material cylinders ..................................... 119Be careful with acid .......................................................................... 120Clean the waterbox ........................................................................... 121Preparation for travel ........................................................................ 122

Special Pumping Situations .................................................................... 122Rod side to piston side pumping (BPA 2000) .................................. 122Quick Clean-out ................................................................................ 123Cold weather pumping...................................................................... 123Preheating the hydraulic oil .............................................................. 124

Maintenance

Filtration.................................................................................................. 126General Information.......................................................................... 126Specific Information ......................................................................... 126

Hydraulic Oils......................................................................................... 128General Information.......................................................................... 128Specific Information ......................................................................... 128

Pressure, Hoses and Fittings ................................................................... 128General Information.......................................................................... 128Specific Information ......................................................................... 129

General Maintenance Tips ...................................................................... 130Torque Specifications ....................................................................... 130Adjusting relief valves. ..................................................................... 130Removal of safety devices. ............................................................... 130

Preventative Maintenance....................................................................... 131Daily Maintenance............................................................................ 131Weekly Maintenance ........................................................................ 132Monthly maintenance ....................................................................... 133Quarterly Maintenance ..................................................................... 136Semiannual maintenance .................................................................. 136Annual maintenance ......................................................................... 140

Scheduled maintenance checklist ........................................................... 141Unscheduled maintenance ...................................................................... 142

Changing rams .................................................................................. 142

Appendix

Hydraulic Oil Viscosity Chart ................................................................ 150Torque Specifications for Metric Bolts .................................................. 151Recommended Emergency Hose Kit ...................................................... 152Fitting Wrench Sizes............................................................................... 153

Straight Fittings................................................................................. 153Banjo Fittings.................................................................................... 153

Maintenance checklist............................................................................. 154Output charts........................................................................................... 155

Using the chart. ................................................................................. 156Nomograph ............................................................................................. 161

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Operation Manual - vii

Using a Nomograph .......................................................................... 161Weld On Ends / Coupling Comparison .................................................. 169MInimum Pipe Wall Thickness .............................................................. 170Decal Location Guides............................................................................ 171

BPA 450 and 500 units ..................................................................... 171BPA 450 and 500 units (continued).................................................. 172WP 750 and 1000 units ..................................................................... 173WP 750 and 1000 units (continued).................................................. 174BPA 2000 units ................................................................................. 175BPA 2000 units (continued).............................................................. 176

Glossary of Terms................................................................................... 178Additional Reading Material................................................................... 183List of Lubricants and Nitrogen.............................................................. 184Hydraulic Schematics ............................................................................. 188HBV 160/260 .......................................................................................... 188Hydraulic Schematics - continued - BPA 450 ........................................ 189Hydraulic Schematics - continued - BPA 500 ........................................ 190Hydraulic Schematics - continued - BPA 2000 ...................................... 191Electric Schematics................................................................................. 192BPA 450/500........................................................................................... 192WP FWD/REV w/FWD VIBRATOR .................................................... 193Electric Schematics BPA 2000 ............................................................... 194Electric Schematics WPT 50/70/95 ........................................................ 195Electric Schematics WPT 50/70/95 - continued ..................................... 196Electric Schematic SP 1000X ................................................................. 197Electric Schematics SP 1000 X - continued (ECM wiring diagram)...... 198Nomographs............................................................................................ 199SP 450 ..................................................................................................... 199Nomographs - continued - SP 500 .......................................................... 200Nomographs - continued - SP 750 - 15................................................... 201Nomographs - continued - SP 750 -18.................................................... 202Nomographs - continued - SP 1000 - 18................................................. 203Nomographs - continued - WPT 95 ........................................................ 204Nomographs - continued - BPA 2000..................................................... 205Output Charts .......................................................................................... 206SP 450 ..................................................................................................... 206Output Charts SP 500.............................................................................. 207Output Charts SP 750 -15 ....................................................................... 208Output Charts SP 750 -18 ....................................................................... 209Output Charts SP 1000............................................................................ 210Output Charts SP 1000............................................................................ 212Output Charts SP 1000XHP.................................................................... 213

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Introduction

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Operation Manual - 9

INTRODUCTION

Manufacturer’s Statement....................................................................... 10 ID Tag Location ........................................................................................ 12 ID Tag....................................................................................................... 13

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Introduction

This operation manual contains unit specifications,product overview information, the safety manual,operation information, and maintenance informationfor your concrete pump unit.

Manufacturer’s Statement

The information contained in the operation manual isabsolutely necessary for the safety, proper setup,operation, maintenance, and servicing of your concretepump. By learning this information and practicing itevery day, you can expect that your concrete pump unitwill give you efficient and reliable service year afteryear.

For your own benefit and safety, read the information inthis manual, and follow the instructions to the letter.

Before you operate your concrete pump for the firsttime, you should read the operating instructions severaltimes through. We recommend that you keep a copywith the concrete pump for quick reference while onthe job site. The general knowledge must be in placebefore you arrive on the job site. Any and all personswho operate a concrete pump must be familiar with theoperating instructions. Even a temporary operator (forexample, if the normal operator is ill or on vacation)must be familiar with the operation instructions. Itstands to reason that a person who has not operated aparticular concrete pump before will not know how tosafely operate that concrete pump. The machine is builtto the latest technology and safety regulations, but itmay still be dangerous to people and property if it isoperated, maintained, repaired, or used incorrectly.

The illustrations contained in this manual are intendedto clarify text passages. They may look slightlydifferent from your unit, but this has only been allowedif it does not fundamentally change the factualinformation.

Technical modifications that are made to units will bedocumented in each new edition of the operationmanual.

Safety alert symbol and signal word explanation

The triangle with the exclamation point inside is usedto alert you to an important safety point and is called a

safety alert symbol

. One of the following signal wordswill appear after the safety alert symbol:

• If the safety alert symbol is followed by thesignal word

DANGER

, it indicates ahazardous situation which, if not avoided,

WILL

lead to

death or serious injury.


WARNING

, it indicates apotentially hazardous situation which, if notavoided,

COULD

result in

death or seriousinjury.


CAUTION

, it indicates apotentially hazardous situation which, if notavoided,

MAY

result in

minor to moderateinjury.

• The signal word

CAUTION

used without thesafety alert symbol means the point addressesa hazard which

COULD

cause

damage toequipment or property.

WARNING

Improper setup / operation creates hazards. Do not operate this machine without training. Understand the warnings in safety manuals and on decals.

0000

99.e

ps

Danger

Warning

Caution

Introduction

Line pumps



Warnings have been placed in the text where needed.Additional information used with the signal words isprinted in decal format, as shown below, to explain thespecific hazard. Occasionally

bold

text is used inaddition to the decal for emphasis.

All persons working near the concrete pump unit mustbe able to recognize hazardous situations. They mustknow how to avoid these situations and how to reactquickly and appropriately whenever hazardoussituations arise.

Heed the warnings shown on the decals!

How to reach us

If you encounter a circumstance that is not covered bythis manual, Schwing America’s Service Departmentwill be more than happy to assist you with all of yourparts and service needs. Call us at either of these #’s:

• Minnesota (main office)

(651) 429 - 0999

• Call Center

1- 888-SCHWING (724-9464)

How to order parts

To place an order for spare parts, you can order on lineat

schwingparts.com

, or you can call our toll free partsline from anywhere in the continental United States,except Minnesota. Parts department hours are Mondaythrough Friday, 6:00 AM to 6:00 PM (central time).Orders will also be accepted via fax, 24 hours/day.

• Spare Parts

1- 888-SCHWING (724-9464)

• Spare Parts

(fax) (651) 429 - 2112

Whenever you call the factory for spare parts orservice, have the model number handy. You can find themodel and serial number on the ID tag that is mountedto the subframe of the unit. For future reference, themodel number and serial number of your machine canbe found on this page.

��DANGER

Hazard and consequence will be shown in this space.

0000

54.e

ps

WARNING


0000

57.e

ps


0000

36.e

ps

CAUTION

Model Number:

Serial Number:

Introduction


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ID Tag Location

The ID tag for this machine is located on the right handside of the tongue on the passenger side as shown inFigure 1.

SWG99a002.eps

Figure 1Location of ID tag and serial number

Introduction

Line pumps



ID Tag

The ID Tag provides information about the entire unitthe pumpkit, the hydraulic systems, and the year ofmanufacture. The unit serial number is on the tag andalso stamped into the subframe directly below the IDtag, as shown in Figure 2.

NOTE!

All numbers used on ID tag illustrations inthis book are for reference only and shouldnot be used in any calculations regardingyour unit. For information specific to yourunit, check the ID tag and serial numberaffixed to the unit itself as shown in Figure1.

If your ID tag is missing

If the tag has been removed from the unit and you needinformation about your concrete pump unit, read theunit serial number that is stamped into the steelsubframe. The unit serial number is located on thetongue directly below the ID tag as shown in Figure 2.When you locate the number, call the Schwing ServiceDepartment for the information. The unit files arearranged by this serial number and the servicepersonnel can find out anything about the unit from thefile that corresponds to this number. New ID tags areavailable from the Service Department when youprovide the unit serial number.

SUBSIDIARY OFSUBSIDIARIA DE

GmbH.Herne / GermanyPhone: (02325) 7871www.schwing.de

5900 Centerville RdWhite Bear, MN 55127Phone: 651-429-0999www.schwing.com

MAX. HYD. PRESSUREPRESIÓN. HID. MAX. Sys. 1 Sys. 2 Sys. 3 Sys. 4 Sys. 5

3010

0673

MODELMODELO

YEARAÑO

SERIAL ## DE SERIE

MAX.SPM

CPM

MATERIALPRESSURE

PSI

PRESIÓN MATERIAL

WEIGHT

PESO

LBS.

PESO DE ENGANCHE

TONGUEWEIGHT

LBS.

This product is covered by one or more U.S. patents - see patent decal Este producto está cubierto por una o más patentes de Estados Unidos – vea la etiqueta

SP ????? 123456789 200?

############

### ### ### ### ###newSPIDtag.eps

Figure 2 ID Tag and serial number

Introduction


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NOTES

Specifications

Operation Manual - Line pumps

SPECIFICATIONS

Concrete Pump Specifications................................................................. 16Hydraulic Pressure Specifications ............................................................ 19

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Specifications

16 Operation Manual - Line pumps

Specifications

Concrete Pump Specifications

MODEL WP 1250 SP 1000X HP SP 1000X

CONCRETE PUMP KIT

80/55 x 1400:180 90/50 x 1000:150 90/50 x 1000:180

Piston side Piston side Piston side

Strokes/minute

(max.) 34 26 35

Max. Output 95 yd

3

/hr 35 yd

3

/hr 70 yd

3

/hr

Power

(Tier3/Com3 engine) Duetz BF4M1013C112 Kw (150 Hp)

TCD 2012100 Kw (133 Hp)

TCD 2012100 Kw (133 Hp)

Power

(Tier2/Com2 engine) Duetz BF4M1013C112 Kw (150 Hp)

Duetz BF4M2012C100 Kw (134 Hp)

Duetz BF4M1013100 Kw (113 Hp)

Power

(Current Electric Motor) 112 Kw (150 Hp) 93 Kw (125 Hp) 93 Kw (125 Hp)

Power

(Former Electric Motor) 93 Kw (125 Hp) 75 Kw (100 Hp) 75 Kw (100 Hp)

Power

(hyd. pumps) Current (C) Former (F) (C)100 Kw (F) 100 (C)84 Kw (F) 70 (C)84 Kw (F) 70

Output

(hyd. pumps) Req’d. 284 L/min (70 gpm) 181 L/min (48 gpm) 246 L/min (65 gpm)

Speed

(hyd. pumps) Diesel 2300 rpm 2500 rpm 2500 rpm

Electric 1800 rpm 1800 rpm 1800 rpm

Pressure

(max. hyd.) 330 bar (4785 psi) 278 bar (4050 psi) 300 bar (4350 psi)

Theoretical Concrete Output 95 yd

3

/hr 35 yd

3

/hr 70 yd

3

/hr

Max. Pressure on Concrete 64.9 bar (942 psi) 100 bar (1450 psi) 75.8 bar (1100 psi)

Max. Horizontal Pumping Distance 297.8 m (977 ft.) 463.3 m (1520 ft.) 353.6 m (1160 ft.)

Max. Vertical Pumping Distance 86.9 m (285 ft.) 146.3 m (480 ft.) 100.6 m (330 ft.)

Max. Aggregate Size 38.1 mm (1.5 in.) 12.7 mm (0.5 in.) 38.1 mm (1.5 in.)

Min. Concrete Slump 0 mm (0 in.) 0 mm (0 in.) 0 mm (0 in.)

Pumping Cylinder Diameter 177.8 mm (7 in.) 152.4 mm (6 in.) 177.8 mm (7 in.)

Stroke Length 1397 mm (55 in.) 990.6 mm (39 in.) 990.6 mm (39 in.)

Differential Cylinder Diameter 79.8 mm (3.14 in.) 89.9 mm (3.54 in.) 89.9 mm (3.54 in.)

Concrete Valve Long Rock HP Short Rock Long Rock

Charging Hopper Height 1295.4 mm (51 in.) 1295.4 mm (51 in.) 1295.4 mm (51 in.)

Fuel Tank Capacity 189.3 L (50 gal.) 113.6 L (30 gal.) 113.6 L (30 gal.)

Gross Weight 4182 kg (9200 lbs.) 3295 kg (7250 lbs.) 3295 kg (7250 lbs.)

Length 5486.4 mm (216 in.) 4165.6 mm (164 in.) 4165.6 mm (164 in.)

Width 1930.4 mm (76 in.) 1651 mm (65 in.) 1651 mm (65 in.)

Height 2209.8 mm (87 in.) 1879.6 mm (74 in.) 1879.6 mm (74 in.)

Remote Control Cable Length 30.5 m (100 ft.) 30.5 m (100 ft.) 30.5 m (100 ft.)

* Contact Schwing for specifications.

Specifications

Operation Manual - Line pumps 17

MODEL SP 750-18X SP 750-15X BPA 2000

CONCRETE PUMP KIT

90/50 x 1000:180 80/50 x 1000:150 120/80 X 1600:200

Piston side Piston side Rod side/Piston side

Strokes/minute

(max.) 35 35 30/24

Max. Output 70 yd

3

/hr 50 yd

3

/hr 118 yd

3

/hr/95 yd

3

/hr

Power

(Tier3/Com3 engine) TCD 201275 Kw (100 Hp)

TCD 201275 Kw (100 Hp)


Power

(Tier2/Com2 engine) Duetz BF4M201275.5 Kw (100 Hp)

Duetz BF4M201275.5 Kw (100 Hp)


Power

(Current Electric Motor) 75 Kw (100 Hp) 75 Kw (100 Hp) 113 Kw (150 Hp)

Power

(Former Electric Motor) 56 Kw (75 Hp) 56 Kw (75 Hp) 113 Kw (150 Hp)

Power

(hyd. pumps) Current (C) Former (F) (C) 60 Kw (F) 43 (C) 60 Kw (F) 43 (C) 86 Kw (F) 86

Output

(hyd. pumps) Req’d.246 L/min (65 gpm) 204 L/min (54 gpm)

300 L/min (79.5 gpm)/434 L/min (115 gpm)

Speed

(hyd. pumps) Diesel 2500 rpm 2500 rpm 2300 rpm

Electric 1800 rpm 1800 rpm 1800 rpm

Pressure

(max. hyd.) 300 bar (4350 psi) 266.7 bar (3867 psi) 300 bar (4350 psi)

Theoretical Concrete Output 70 yd

3/hr 50 yd3/hr 118 yd3/hr

Max. Pressure on Concrete75.8 bar (1100 psi) 75.8 bar (1100 psi)

60 bar (870 psi)/108 bar (1568 psi)

Max. Horizontal Pumping Distance 353.6 m (1160 ft.) 353.6 m (1160 ft.) 457 m (1500 ft.)

Max. Vertical Pumping Distance 100.6 m (330 ft.) 100.6 m (330 ft.) 121 m (400 ft.)

Max. Aggregate Size 38.1 mm (1.5 in.) 38.1 mm (1.5 in.) 63 mm (2.5 in.)

Min. Concrete Slump 0 mm (0 in.) 0 mm (0 in.) 0 mm (0 in.)

Pumping Cylinder Diameter 177.8 mm (7 in.) 152.4 mm (6 in.) 200 mm (8 in.)

Stroke Length 990.6 mm (39 in.) 990.6 mm (39 in.) 1600 mm (63 in.)

Differential Cylinder Diameter 89.9 mm (3.54 in.) 79.9 mm (3.14 in.) 120 mm (4.75 in.)

Concrete Valve Long Rock Long Rock M Rock

Charging Hopper Height 1295.4 mm (51 in.) 1295.4 mm (51 in.) 1373 mm (54 in.)

Fuel Tank Capacity 113.6 L (30 gal.) 113.6 L (30 gal.) 189 L (50 gal.)

Gross Weight 3250 kg (7150 lbs.) 3159 kg (6950 lbs.) 5443 kg (12000 lbs.)

Length 4165.6 mm (164 in.) 4165.6 mm (164 in.) 5816 mm (229 in.)

Width 1651 mm (65 in.) 1651 mm (65 in.) 1930 mm (76 in.)

Height 1879.6 mm (74 in.) 1879.6 mm (74 in.) 2373 mm (93.4 in.)

Remote Control Cable Length 30.5 m (100 ft.) 30.5 m (100 ft.) 30.5 m (100 ft.)

Electric Motor (Optional)* * * *


Specifications


MODEL SP 450 SP 500

CONCRETE PUMP KIT 80/50 x 1000:150 80/50 x 1000:150

Strokes/minute (max.) 27 @ 2300 RPM 32.5 @ 2500 RPM

Max. Output 35 yd3/hr 45 yd3/hr

Power (Tier3/Com3 engine) Duetz BF4L1011F49 Kw (66 Hp)

TD 2011L0454 Kw (73 Hp)

Power (Tier2/Com2 engine) Duetz BF4L1011F49 Kw (66 Hp)

Duetz BF4L1011F52 Kw (70 Hp)

Power (Electric Motor) 60 Hp 75 HP

Power (hyd. pumps) 34 Kw 41 Kw

Output (hyd. pumps) Req’d. 190 L/min (50 gpm) 190 L/min (50 gpm)

Speed (hyd. pumps) 2300 RPM 2500 RPM

Pressure (max. hyd.) 266 bar (3867 psi) 266 bar (3867 psi)

Theoretical Concrete Output 35 yd3/hr 45 yd3/hr

Max. Pressure on Concrete 76 bar (1100 psi) 76 bar (1100 psi)

Max. Horizontal Pumping Distance 353.6 m (1160 ft.) 353.6 m (1160 ft.)

Max. Vertical Pumping Distance 100.6 m (330 ft.) 100.6 m (330 ft.)

Max. Aggregate Size 25.4 mm (1.0 in.) 25.4 mm (1.0 in.)

Min. Concrete Slump 0 mm (0 in.) 0 mm (0 in.)

Pumping Cylinder Diameter 152.4 mm (6 in.) 152.4 mm (6 in.)

Stroke Length 990.6 mm (39 in.) 990.6 mm (39 in.)

Differential Cylinder Diameter 79.8 mm (3.14 in.) 79.8 mm (3.14 in.)

Concrete Valve Short Rock Short Rock

Charging Hopper Height 1219.2 mm (48 in.) 1219.2 mm (48 in.)

Fuel Tank Capacity 75.7 L (20 gal.) 75.7 L (20 gal.)

Gross Weight 2268 kg (5000 lbs.) 2359 kg (5200 lbs.)

Length 4318 mm (170 in.) 4318 mm (170 in.)

Width 1676.4 mm (66 in.) 1676.4 mm (66 in.)

Height 1879.6 mm (74 in.) 1879.6 mm (74 in.)

Remote Control Cable Length 30.5 m (100 ft.) 30.5 m (100 ft.)

Electric Motor (Optional)* * *


Specifications

Operation Manual - Line pumps 19

Hydraulic Pressure SpecificationsOil should be at 40° to 50° Celsius before testing.

Concrete Pump bar (PSI)

WP-1250 330 (4785)SP-1000HP 280 (4050)SP-1000 300 (4350)SP-750-18 300 (4350)SP-750-15 266 (3867)SP 450 266 (3867)SP 500 266 (3867)BPA-2000 300 (4350)Agitator 125 (1812)Accumulator dump valve 200 (2900)Accumulator secondary relief 220 (3200)Soft switch relief 100 (1450)Stroke limiter circuit 0-25 (0-363)Nitrogen pressure 100 (1450)

Specifications


NOTES

Safety

Line pumpsStartup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve models:Frame files:Safety.fm Operation Manual - 21

SAFETY

How to Order Additional Safety Manuals .................................................. 22Safety Manual (Separate Document) ........... Immediately following page 24

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Safety

Operation Manual - Line pumps22 revDate

SafetyThe information contained in this section of theoperation manual is absolutely necessary for the safesetup, operation, maintenance, and servicing of yourconcrete pump and placing boom.

The Safety Manual is a separate document from therest of this manual. Because it is a separate document,the page numbering and formatting will be differentthan the rest of your manual. This was done to allowthe Safety Manual to be inserted in many differentpublications while appearing exactly the same in allplaces. The Safety Manual has its own alphabeticalindex, which is found at the end of the Safety Manual.

How to Order Additional Safety ManualsTo place an order for additional Safety Manuals (or anyother manual), you can call our toll free parts line fromanywhere in the continental United States exceptMinnesota, where you must use the main Schwingoffice number. Schwing Spare Parts Department hoursare Monday through Friday, 6:00 AM - 9:00 PM(Central Time). Orders will also be accepted via fax, 24hours/day.

We will ship one set of each of the following manualsfree of charge for each unit that is listed with its serialnumber and current location:

Safety Manual,• English: . . . . . . . . . . . . . . . . . . . . . . . . . .30327535• Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381024

Co-worker Safety Rules, laminated,• English: . . . . . . . . . . . . . . . . . . . . . . . . . .30381022 • Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381027

Co-worker Safety Rules, unlaminated,• English: . . . . . . . . . . . . . . . . . . . . . . . . . .30381023• Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381028

Small line Safety Manual,• English: . . . . . . . . . . . . . . . . . . . . . . . . . .30381680• Spanish: . . . . . . . . . . . . . . . . . . . . . . . . .30381841

Schwing phone numbers• Spare Parts . . . . . . . . . . . . . . . . . (888) SCHWING• Spare Parts (fax) . . . . . . . . . . . . . .(651) 429 - 2112• Spare Parts (toll free fax) . . . . . . .(877) 554 - 5119• In Minnesota,

or outside of continental U.S. . . . .(651) 429 - 0999

NOTE!To order manuals, copy the order formshown on page 24, and Fax it to Schwing atone of the above numbers, or mail it to:

Schwing Spare Parts Department5900 Centerville RdSt. Paul, MN, 55127

Safety

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August 29, 2008

safemanbulletinletter.fm

Safety/Service Bulletin 1023-08

Subject: Release of Safety Manual version 6.x.1

Dear Schwing Customer,

The Safety Manual has been updated to version 6.0.1 and has several changes, most of which pertain to the more common incidents currently being reported in the concrete pumping industry (hose whipping, tip overs and electrocution). One notable pagination change occurred. The pipewall thickness chart, which has always appeared on page 73 of the Safety Manual, has been pushed back to page 75. In the past, releases such as this would include the complete paperback manual and a non-laminated version of the updated Co-worker Safety Rules. In an effort to “Go Green”, we have decided to ship a CD containing six PDF files: Version 6.0.1 of Safety Manual (English & Spanish), version 6.0.1 of the Co-worker Safety Manual (English & Spanish), and version 6.0.1 of the Line Pump Safety Manual (English & Spanish). This package, as in the past, also includes an order form for hard copies of any of those documents. Just fill out the attached form(s) and fax it to us at the number listed. We will ship one set of manuals free of charge for each unit that is listed with its serial number and current location. Additional manuals are available at a nominal fee. The Co-worker Safety Rules are available as laminated books intended to be kept on the pump for easy reference. Please instruct your operators to make the co-worker information available to the placing crew and laborers, and to read the information to the workers if they believe the workers wouldn’t understand the printed text. If you are planning any safety training for your customers, the Co-worker Safety Rules booklet is also available in a non-laminated version at a fraction of the cost. If you choose to order the un-laminated version, the part numbers are 30381023 for English and 30381028 for Spanish. You could also print them yourself from the file on the enclosed disc. Of course, the non-laminated version is not intended to be kept on the pump. It is our objective to get a copy of each of these publications into the hands of every operator and the workers around the pump. Please help us make the Safety Manual effective for jobsite safety by obtaining a copy for each of your operators, and encourage them to read and understand the rules. Older versions of the manual should be discarded when the new version is in hand.

Thank you in advance for your consideration in this matter.

Best Regards,

Danny L. MaceManager, Product Safety DepartmentSchwing America, Inc.

Safety


a

Safety Manual v 6.0.1 Order Form

Fax # (651) 429 - 8261(publications dept.)

Please complete this form and mail to:

Or send via fax to:

5900 Centerville RoadWhite Bear, Mn. 55127Telephone (651) 429-0999Attention: Publications

Feel free to copy or otherwise reproduce this form if more copies are needed.

Company:

Street Address:

City, State, Zip:

Attention: Phone ( )

We cannot ship manuals to a P.O. box

Safety Manual, Bound, English v 6.0.1 .................................................................................. Part #30327535Safety Manual, Bound, Spanish v 6.1.1 .................................................................................. Part #30381024Co-worker, Bound & Laminated, English v 6.0.1 .................................................................... Part #30352799Co-worker, Bound & Laminated, Spanish v 6.1.1 .................................................................. Part #30381027Line Pump, Bound, English v 6.0.1 ......................................................................................... Part #30381680Line Pump, Bound, Spanish v 6.1.1 ....................................................................................... Part #30381841

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internal250:servicebulletins:601order form.ai

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Overview

Line pumpsStartup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve models:Frame files:Overview.fm Operation Manual - 25

OVERVIEW

Machine Description ................................................................................. 27BPA Circuit Diagrams ............................................................................... 32Component Locations............................................................................... 72Safety Devices .......................................................................................... 90

swg99a001.eps

Overview


Product Overview

First Commissioning

Installation of your new unitWhen your new Schwing was delivered, it wasaccompanied by several documents in addition to thisoperation manual. One of those important documents iscalled the “DELIVERY INSPECTION REPORT”.Each of the 35 items listed should be checked beforeyour new pump is sent to the first job.

Operational Repair Required

Comments*(If repair is required)

1. Engine Coolant2. Engine oil level3.Transmission oil level4. Oil level system l and ll5. Oil level system lll6. Transfer case or FTD oil level7. Oil in gear compartment of Hyd. Pump 18. Oil level in dist. gear box (banana pumps)9. Oil level in agitator gear box10. Flushing oil level (gate valve system)11. Oil level in compressor12. Agitator greased13. Rock valve greased (if equipped)14. Drive line greased15. Outriggers & boom greased16. Manual & remote throttles set to proper RPM ( RPM)17. Setting of relief valve system l18. Setting of relief valve system ll19. Setting of relief valve system lll20. Pressure gauges work system l&ll&lll21. Hydraulic lines checked for leakage (heat oil to 80˚ c)22. Hydraulic oil cooler checked for leakage and proper air flow23. Water pump24. Agitator25. Forward-reverse for pumpkit26. Outriggers27. Remote control (boom) functions28. Manual check of all hand valves29. Holding valves on boom30. All boom pin retainers in place31. End hose cable hook installed32. Tail light and clearance lights33. Safety decals (see decal sheet)34. Tools/Spare Parts (see tool check list)35. Visual inspection of paint job* Please note any other comments on back of white copy

Overview


Machine DescriptionIt is recommended that you read this section of themanual while you are near the concrete pump so thatyou can identify the components that are discussed.

The Schwing trailer-mounted concrete pump ismounted on a subframe which is mounted on a trailerchassis. The pump is hydraulically driven.

Emergency Stop switchesPressing one of the RED EMERGENCY PUSH STOPswitches (Figure 3) will stop the engine.

SWG98n135.eps

Figure 3Emergency Stop Switches (4)

Overview


Concrete pump hydraulic pumpsThe hydraulic pumps for the concrete pump circuit arevariable displacement piston pumps. They arehorsepower controlled, which means that as pressurerises, the flow decreases, so the power consumptionremains constant. We use this type of pump so theengine will not bog down under hard pumpingconditions. The pumps also accept external signals forcontrol of the output. At Schwing, we route signals tothe pump from the hydraulic stroke limiter. The neteffect is to tell the pump to put out less oil perrevolution, as required by the pump operator (Figure4).

Concrete Pump CircuitThe method of getting the hydraulic cylinders tochange direction at the appropriate times is the subjectof several paragraphs on the following pages.

The hydraulic pumps that supply oil to the concretepump kit are made to be able to adjust the amount ofoil they deliver both by internal pressure sensingdevices and by adjustment of external valves (thestroke limiter).

This Operation Manual will deal with a rock type ofconcrete valve. Contact Schwing Service Departmentat (651) 429-0999 for questions regarding flat gates.

Shown in Figure 5 are the components of the concretepump control system.

4_Pumps.tiff

Figure 4Main Hydraulic Pump and External

Connections

Overview


S1

S2

S3

192

20

boom

1

13

14

16

6

5

9A

9B

2110A 10B

10C

10D

7

4

25

24

2322

3

8A 8B

12

11

15 17

hiflopmk.eps

18

Figure 5The fully hydraulic pump control system (for hi-flo pumpkit)

1. Hydraulic oil reservoir 14. Pilot to close accumulator dump valve

2. Main hydraulic pumps 15. Manual accumulator dump valve

3. Main pressure relief valve 16. Accumulator pressure maintenance check valve

4. Directional control valve S1 17. Accumulator relief valve

5. Rock Valve slewing cylinder 18. Accumulator pressure gauge

6. Directional control valve S3 19. Accumulator hydraulic pump

7. Directional control valve S2 20. Accumulator redundant relief, E-stop manifold

8A - 8B. Differential hydraulic cylinders 21. NG 10 valve for forward/reverse

9A - 9B. Reversing valves (MPS) 22. Soft switch relief valve

10A - 10D. Check valves 23. Soft switch shutoff valve

11. Main shutoff valve (Ball cock) 24. Soft switch reversing valve

12. Hydraulic return filter with bypass valve 25. Main flow poppet valve

13. Accumulator

Overview


The term “differential cylinder” refers to the fact thateach of the hydraulic cylinders that push the concretehave an area difference (referred to as an “areadifferential”) between the two sides of the piston. Thisarea differential is due to the fact that the rod extendsonly from one side of the piston, and not the other. Therock slewing cylinders on this model are single acting.They have no piston, other than a false piston toprevent the rod from coming out of the cylinder.

Figure 6The rock valve slewing cylinders (shown as item 5 in Figure 3)

Figure 7“S” valve diagram explanation for S2 and S3 valves

(shown as items 6 and 7 in Figure 3)

Overview


The switching valves have a logic function, in that theysense multiple pressures simultaneously and will routeoil from the poppet end port to the output port ONLY ifthe pressure from the poppet end port exceeds thepressure at the spring end port by more than 2:1.

Figure 8Differential hydraulic cylinder diagram explanation

(shown as items 8A and 8B in Figure 3)

Figure 9Switching valve diagram explanation

Overview


BPA Circuit DiagramsThe following diagrams A through D show theswitching functions of the fully hydraulic pump controlsystem plumbed on PISTON SIDE with simplifiedschematics. The agitator, circuits are not shown.

Phase A• As soon as you start the engine, the

accumulator hydraulic pump (19) beginspumping high pressure oil (red) to charge theaccumulator circuit (13).

• Shown in the beginning position in phase Aschematic. High pressure oil (red) continues toflow into the accumulator circuit until theaccumulators (13) are charged to the pressurecut-off point of the accumulator hydraulicpump (19). When the cut-off point is reached,the accumulator pump reduces the hydraulicoil flow until there is just enough to maintainthe cut-off pressure.

• The high pressure oil (red) from theaccumulator circuit flows through the S3directional control valve (6), which is in theparallel position, into the right-hand side oilport of the rock slewing cylinder (5).

• The rod of the rock slewing cylinder (5) movesto the end position, if it has not reached thereyet.

• The S-1 directional control valve (4), whichcontrols whether the unit pumps in forward,neutral, or reverse, is put into the forwardposition.

• A pilot signal (high pressure oil) is routed fromthe accumulator circuit to the right side endcap of the S2 directional control valve (7),which moves into the parallel position.

• High pressure oil (red) flows from the mainhydraulic pump (2) through the parallelposition of the S2 valve (7) into the piston sideof the right side differential cylinder (8B). Thecylinder extends, pushing concrete out of the

material cylinder, through the rock valve, andinto the pipeline. (This is called the pressurestroke.)

• The oil that is forced out of the rod side of theright differential cylinder (8B) flows throughhoses into the piston side of the left differentialcylinder (item 8A). This oil is called rockingoil (orange).

• The rocking oil forces the left side differentialcylinder (8A) to retract, which creates avacuum in the material cylinder. The right sidematerial cylinder fills with concrete. (This iscalled the suction stroke.)

• The oil from the rod side of the left differentialcylinder (8A) is routed back to the tankthrough the return filter (12). The low pressureoil is shown in green.

• The oil shown as blue is at rest, or pressureless,such as the oil in the reservoir.

Overview


2.0mm 300

bar

P

Psp

Mp

Mp1

T

6.75mm

6.75mm

Phase A KEY

Zero Pressure(Tank, or oil at rest)

Low Pressure

Soft Switch Pressure

Rocking Oil Pressure

High Pressure

4

5

6

7

8A

9A

9B

10A

11

13

16 14 15 17 18

20

10B

8B

BPAcircuitA.eps1

2

3

12 19 21 22

23

Overview


Phase BPlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• The right side differential cylinder (8B)reaches top dead center. If there is not enoughrocking oil in the loop to bring the left sidedifferential cylinder (8A) to the bottom deadcenter position, oil is added now through checkvalve (10A.)

• The left side differential cylinder (8A) reachesbottom dead center. As the piston reaches theguide bushing, it exposes a port to the poppetend port of the switching valve (9B), whichbecomes connected to high pressure oil. Thespring end port of the switching valve (9B) isconnected to low pressure oil (green), so theswitching valve opens, sending high pressureoil (red) toward the left side end cap of the S3valve (6). A pilot signal is also sent to the softswitch reversing valve (21), creating a passageway to the soft switch relief valve (22). Thisreduces system pressure allowing for asmoother shift.

• The pressure signal reaches the S3 valve endcap (6), pushing the valve to the right, whichplaces it into the cross-over position.

• The oil on the right end cap of the S3 valve (6)flows through the reversing valve(20) back totank (1).

• In the cross-over position, the S3 valve (6)routes oil from the accumulator to the extendport of the rock valve slewing cylinder (5). Thecylinder begins to extend to the right.

• The oil from the left side of the rock valveslewing cylinder (5) is routed back to tank (1).

• A pilot signal (high pressure oil) is routed fromthe accumulator circuit to the left side end capof the S2 directional control valve (7).

• As the rock valve slewing cylinder (5) extends,pressure in the accumulator circuit falls. Highpressure oil (red) continues to flow into theaccumulator circuit until the accumulators (13)are charged to the pressure cut-off point of theaccumulator hydraulic pump (19). When thecut-off point is reached, the accumulator pumpreduces the hydraulic oil flow until there is justenough to maintain the cut-off pressure.

Overview


2.0mm 300

bar

P

Psp

Mp

Mp1

T

6.75mm

6.75mm

Phase B KEY


Low Pressure



High Pressure

4

5

6

7

8A

9A

9B

10A

11

13

16 14 15 17 18

20

10B

8B

BPAciruitB.eps1

2

3

12 21 22

23

19

Overview


Phase CPlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• The rock valve slewing cylinder (5) reaches theend position.

• High pressure oil (red) continues to flow intothe accumulator circuit until the accumulators(13) are charged to the pressure cut-off point ofthe accumulator hydraulic pump (19). Whenthe cut-off point is reached, the accumulatorpump reduces the hydraulic oil flow until thereis just enough to maintain the cut-off pressure.

• The S2 valve (7) has finished sliding to theright. Oil is now routed from the mainhydraulic pump (2) to the piston side of the lefthand differential cylinder (8A).

• As the left hand differential cylinder (8A)moves, high pressure oil (red) reaches thespring end port of the switching valve (9B).The valve closes by the pressure applied to thespring end port. This removes the pilot signalto the left side of the S3 directional controlvalve (6).

• As the left side differential cylinder (8A)extends, the material cylinder, the concretefrom stage A is forced out of the materialcylinder and into the delivery pipeline.(Pressure stroke.)

• The oil from the piston side of the left sidedifferential cylinder (8A) travels through thehoses to the piston side of the right handdifferential cylinder (8B), forcing it to retract,which creates a void in the material cylinderand concrete begins to flow in to fill that void.(Suction stroke.)

• The oil from the rod side of the right handdifferential cylinder (8B) is routed through theS2 valve (7), through the return filter (12), andback to tank (1).

Overview


2.0mm 300

bar

P

Psp

Mp

Mp1

T

6.75mm

6.75mm

Phase C KEY


Low Pressure



High Pressure

4

5

6

7

8A

9A

9B

10A

11

13

16 14 15 17 18

20

10B

8B

BPAcircuitC.eps1

2

3

12 19 21 22

23

Overview


Phase DPlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• The left side differential cylinder (8A) extendsto top dead center. The right side differentialcylinder (8B) retracts to bottom dead center.

• Any excess rocking oil is routed to the tank (1)across check valve (10B).

• When the left side differential cylinder is in thetop dead center position, pressure is applied tothe end port of the switching valve (9A.) Theswitching valve opens and sends a pilot signalto the right side end cap of the S3 valve (6).

• The S3 valve (6) moves to the left in responseto the pilot signal, putting it into the parallelposition.

• High pressure oil (red) is routed from theaccumulator circuit through the S3 valve (6) tothe right-hand extend port of the rock valveslewing cylinder (5). A signal line is also sentto the right side of the S2 valve (7).

• The rock valve slewing cylinder (5) extends,sending the left side oil back to tank (1)through the S3 valve (6).

• As the rock slewing cylinder (5) extends,pressure in the accumulator circuit falls. Highpressure oil (red) continues to flow into theaccumulator circuit until the accumulators (13)are charged to the pressure cut-off point of theaccumulator hydraulic pump (19). When thecut-off point is reached, the accumulator pumpreduces the hydraulic oil flow until there is justenough to maintain the cut-off pressure.

Overview


2.0mm 300

bar

P

Psp

Mp

Mp1

T

6.75mm

6.75mm

Phase D KEY


Low Pressure



High Pressure

4

5

6

7

8A

9A

9B

10A

11

13

16 14 15 17 18

20

10B

8B

BPAcircuitD.eps1

2

3

12 19 21 22

23

Overview


Phase EPlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• This brings us back to phase A. The machinehas made one complete cycle, which consistsof two suction strokes and two pressurestrokes.

Overview


2.0mm 300

bar

P

Psp

Mp

Mp1

T

6.75mm

6.75mm

Phase E KEY


Low Pressure



High Pressure

4

5

6

7

8A

9A

9B

10A

11

13

16 14 15 17 18

20

10B

8B

BPAcircuitE.eps1

2

3

12 19 21 22

23

Overview


WP Circuit DiagramThe following diagrams A through D show theswitching functions of the fully hydraulic pump controlsystem plumbed on PISTON SIDE with simplifiedschematics. The agitator circuits are not shown.

Phase APlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• As soon as you start the engine, theaccumulator hydraulic pump (19) beginspumping high pressure oil (red) to charge theaccumulators.(13).

• Shown in the beginning position in phase Aschematic. High pressure oil (red) continues toflow into the accumulator circuit until theaccumulators (13) are charged to the pressurecut-off point of the accumulator hydraulicpump (19). When the cut-off point is reached,the accumulator pump reduces the hydraulicoil flow until there is just enough to maintainthe cut-off pressure.

• The high pressure oil (red) from theaccumulator circuit flows through the S3directional control valve (6), which is in theparallel position, into the right-hand rockslewing cylinder port(5).

• The rod of the rock slewing cylinder (5) fullyextends to the right, if not already extended.

• The S1 directional control valve (4), whichcontrols whether the unit pumps in forward,neutral, or reverse, is put into the forwardposition by energizing one of the coils on thesolenoid valve(20).

• A pilot signal (high pressure oil) is routed fromthe accumulator circuit to the end cap of the S2directional control valve (7), which moves intothe parallel position.

• High pressure oil (red) flows from the mainhydraulic pump (2) through the parallelposition of the S2 valve (7) into the piston sideof the left hand differential cylinder (8A). Thecylinder extends, pushing concrete out of thematerial cylinder, through the rock valve, andinto the pipeline. (This is called the pressurestroke.)

• The oil that is forced out of the rod side of theright differential cylinder (8A) flows throughhoses into the rod side of the right differentialcylinder (item 8B). This oil is called rockingoil (orange).

• The rocking oil forces the right sidedifferential cylinder (8B) to retract, whichcreates a vacuum in the material cylinder. Theright side material cylinder fills with concrete.(This is called the suction stroke.)

• The oil from the piston side of the rightdifferential cylinder (8B) is routed back to thetank.

• The oil shown as blue, such as the oil in thereservoir, is at rest, or pressureless.

Overview


1.2

2.0mm 300

bar

P

Psp

Nitrogen pressure set at 100 bar (1450 PSI)

XB1XA1

B3A3

6.75mm

6.75mm

2.4mm

S3

2.4mm

1.3

1.3

1.0

1.0

ZK2ZK1

TSP

ZS2ZS1

BA

X3

XBXA

S2

A1

XA

XR

B1

XB

XP

P1

T1

MX

X1

T

X3

1.4

1.1

100bar

310 bar

20 bar

1.7mm

PR

A B

1.1mm

S1

P2

MP

T2

1.7mm

S2

A1

XA

Mp

Mp1

T

WPhifloA.eps

Phase A Hi-Flo KEY


Low Pressure



High Pressure

1

2

3

4

5

6

7

9A

12

10B 10A

11

13

16 14 15 17

19

9B

22

23

8A 8B

10C

10D

20

24

18

Overview


Phase BPlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• The right side differential cylinder (8B)reaches top dead center. If there is extrarocking oil in the loop that the right sidedifferential cylinder (8A) cannot retract to thebottom dead center position, then oil isremoved now through check valve 10D.

• The right side differential cylinder (8A)reaches bottom dead center. As the pistonreaches the guide bushing, it exposes a port tothe end cap of the switching valve (9A), whichbecomes connected to high pressure oil (red).The left end cap of the switching valve (9A) isconnected to low pressure oil (orange), so theswitching valve slides into the parallelposition, sending high pressure oil (red) towardthe end cap of the S3 valve (6).

• The pressure signal reaches the S3 valve endcap (6), pushing the valve into the cross-overposition.

• The oil on the right end cap of the S3 valve (6)flows back to tank (1).

• In the cross-over position, the S3 valve (6)routes oil from the accumulator to the port onthe right-hand rock valve slewing cylinder (5).The cylinder begins to extend.

• The oil from the left hand side of the rockvalve slewing cylinder (5) is routed back totank (1).

• Shown in beginning position in phase Bschematic. A pilot signal (high pressure oil) isrouted from the accumulator circuit to the leftside end cap of the S2 directional control valve(7). The S2 valve slides into the cross-overposition.

• As the rock slewing cylinder (5) retracts,pressure in the accumulator circuit falls. Whenit drops below the set point of the accumulatorhydraulic pump cut-off pressure, theaccumulator hydraulic pump (19) increases theflow of hydraulic oil to charge the accumulatorcircuit (13).

Overview


1.2

2.0mm 300

bar

P

Psp


XB1XA1

B3A3

6.75mm

6.75mm

2.4mm

S3

2.4mm

1.3

1.3

ZK2ZK1

TSP

ZS2ZS1

BA

X3

XBXA

S2

A1

XA

XR

B1

XB

XP

P1

T1

MX

X1

T

X3

1.4

1.1

100bar

310 bar

20 bar

1.7mm

PR

A B

1.1mm

S1

P2

MP

T2

1.7mm

S2

A1

XA

Mp

Mp1

T

WPhifloB.eps

Phase Ba Hi-Flo KEY


Low Pressure



High Pressure

1

2

3

4

5

6

7

9A

12

10B 10A

11 13

16 14 15 17

19

9B

22

23

8A 8B

10C

10D

20

24

18

1.0

1.0

Overview


Phase CPlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• The rock valve slewing cylinder (5) has fullyextended

• High pressure oil (red) continues to flow intothe accumulator circuit until the accumulator(13) is charged to the pressure cut-off point ofthe accumulator hydraulic pump (19). Whenthe cut-off point is reached, the accumulatorpump reduces the hydraulic oil flow until thereis just enough to maintain the cut-off pressure.

• The S2 valve (7) has finished sliding. Oil isnow routed from the main hydraulic pump (2)to the piston side of the right hand differentialcylinder (8B).

• As the right hand differential cylinder (8B)moves, rocking oil (orange) reaches the leftend cap of the switching valve (9A). The valvecloses by the pressure applied and the force ofthe return spring. This removes the pilot signalto the left side of the S3 directional controlvalve (6).

• As the right side differential cylinder (8B)extends, the concrete in the material cylindersfrom stage A is forced out into the deliverypipeline. (Pressure stroke.)

• The oil from the rod side of the right sidedifferential cylinder (8B) travels through thehoses to the rod side of the right handdifferential cylinder (8A), forcing it to retractwhich it creates a void in the material cylinderand concrete begins to flow in to fill that void.(Suction stroke.)

• The oil from the piston side of the left handdifferential cylinder (8A) is routed through theS2 valve (7), and back to tank (1).

Overview


1.2

2.0mm 300

bar

P

Psp


XB1XA1

B3A3

6.75mm

6.75mm

2.4mm

S3

2.4mm

1.3

1.3

ZK2ZK1

TSP

ZS2ZS1

BA

X3

XBXA

S2

A1

XA

XR

B1

XB

XP

P1

T1

MX

X1

T

X3

1.4

1.1

100bar

310 bar

20 bar

1.7mm

PR

A B

1.1mm

S1

P2

MP

T2

1.7mm

S2

A1

XA

Mp

Mp1

T

WPhifloC.eps

Phase C Hi-Flo KEY


Low Pressure



High Pressure

1

2

3

4

5

6

7

9A

12

10B 10A

11 13

16 14 15 17

19

9B

22

23

8A 8B

10C

10D

20

24

18

1.0

1.0

Overview


Phase DPlease note that right and left refer to the orientationyou would have if you were looking from the trailerhitch towards the front of the unit.

• The right side differential cylinder (8B)extends to top dead center. The right sidedifferential cylinder (8A) approaches bottomdead center.

• If there is not enough rocking oil to completelyextend cylinder 8A, rocking oil will now beadded through check valve 10C.

• When the left side differential cylinder is in thetop dead center position, pressure is applied tothe right end cap of the switching valve (9B).The left end cap of the switching valve isconnected to low pressure, so the valve slidesinto the parallel position. The switchingvalveroutes the pilot signal to the right side end capof the S3 valve (6).

• The S3 valve (6) moves to the parallel positionin response to the pilot signal. The oil in theleft side end cap of the S3 valve (6) escapes totank.

• High pressure oil (red) is routed from theaccumulator circuit through the S3 valve (6) tothe extend port of the rock valve slewingcylinder (5).

• The rock valve slewing cylinder (5) extends tothe right, sending the retract side oil back totank (1) through the S3 valve (6).

• As the rock slewing cylinder (5) extends,pressure in the accumulator circuit falls. Whenit drops below the set point of the accumulatorhydraulic pump cut-off pressure, theaccumulator hydraulic pump (19) increases theflow of hydraulic oil to charge the accumulatorcircuit (13).

• At the same time that the rock valve cylinder isextending, a high pressure pilot signal is sentto the right end port of the S2 spool. It slidesinto the parallel position. When it hascompleted the travel, oil is routed from themain pump (2) to the rod side of the right handdifferential cylinder (8A).

This brings us back to phase A. The machine has madeone complete cycle, which consists of two suctionstrokes and two pressure strokes.

Overview


1.2

2.0mm 300

bar

P

Psp


XB1XA1

B3A3

6.75mm

6.75mm

2.4mm

S3

2.4mm

1.3

1.3

ZK2ZK1

TSP

ZS2ZS1

BA

X3

XBXA

S2

A1

XA

XR

B1

XB

XP

P1

T1

MX

X1

T

X3

1.4

1.1

100bar

310 bar

20 bar

1.7mm

PR

A B

1.1mm

S1

P2

MP

T2

1.7mm

S2

A1

XA

Mp

Mp1

T

WPhifloD.eps

Phase D Hi-Flo KEY


Low Pressure



High Pressure

1

2

3

4

5

6

7

9A

12

10B 10A

11 13

16 14 15 17

19

9B

22

23

8A 8B

10C

10D

20

24

18

1.0

1.0

Overview


BPA 2000 Circuit Diagram

Phase AWith S1 valve (1) in the forward position, and the S2valve (2) in the left position oil flows to the right handdifferential acting on the rod side. Oil from the pistonside of the right hand differential oil is passed to thepiston side of the left hand differential and the rod sideoil of the left hand differential is directed back to tankvia valves S2 and S1 and through the filter (7). Oildirected through the S3 has the rock valve shiftcylinder held in the retracted (right) position so thatconcrete from the left hand material cylinder is beingpushed into the delivery pipe line. Concrete from thehopper is being sucked into the right hand materialcylinder.

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1

12.5 mm 12.5 mm

To Fwd/Rev Handvalve

Overview


Phase BThe differential cylinders have reached the end of theirstroke position*. Switching valve (5) is sending a highpressure signal to the left hand end cap of S3 valve (3).Oil from the right hand end cap of the S3 valve (3) isrelieved via check valve (15), the S2 valve (2), S1 valve(1), filter (7) and back to the hydraulic tank.

NOTE!If the left hand differential has not fullyextended at this point due to not enoughloop oil, high pressure oil will continue toflow through check valve (17) on the righthand differential until the left handdifferential is fully extended.

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

12.5 mm 12.5 mm


Overview


Phase CHigh pressure oil from switching valve (5) has nowshifted the S3 valve (3) fully to the right hand position.At this point the pressure oil to the rock valve shiftcylinder (4) is changed and the right hand side of thecylinder is getting oil so that the cylinder will extend.Oil from the left hand side of the rock valve shiftcylinder is routed to tank via valves (3, 1) and filter (7).

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

12.5 mm 12.5 mm


Overview


Phase DThe rock valve shift cylinder (4) has now fullyextended. At this point a signal is sent to the left handend cap of the S2 valve (2) from a signal port on therock valve shift cylinder (4). As the S2 valve (2) shiftsto the right oil from the right hand end cap of the S2valve (2) is routed to the hydraulic tank via check valve(13), valves (3, 1) and the filter (7).

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1


4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1

12.5 mm 12.5 mm

Overview


Phase EWith the S2 valve (2) fully shifted and held in the righthand position, pressure oil is routed through the S1valve (1) and the S2 valve (2) to the rod side of the lefthand differential cylinder. Please note that while theleft hand differential cylinder is starting to retract,check valve (17) must close otherwise the right handdifferential cylinder will not extend.

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

Note: Check Valve Must Close

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1


12.5 mm 12.5 mm

Overview


Phase FPressure oil is being routed through the S1 valve (1)and S2 valve (2) to the rod side of the left handdifferential cylinder causing it to retract. Oil from thepiston side of the left hand differential cylinder ispassed to the piston side of the right hand differentialvia the loop hose. The oil on the rod side of the righthand differential is going through valves (2 and 1),filter (7) and back to the tank. Oil directed through theS3 valve has the rock valve shift cylinder held in theextended position so that concrete from the right handmaterial cylinder is being pushed into the delivery pipeline and concrete from the hopper is being sucked intothe left hand material cylinder.

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20


12.5 mm 12.5 mm

Overview


Phase GThe left hand differential cylinder has now fullyretracted*. Switching valve (6) is sending a highpressure signal to the right hand end cap of the S3valve (3). Oil from the left hand end cap of the S3 valve(3) is relieved via check valve (14), the S2 valve (2), S1valve (1), filter (7) and back to the hydraulic tank.

NOTE!If the left hand differential cylinder has notfully retracted at this point because of tomuch loop oil, high pressure oil willcontinue to flow through check valve (16)and back to the hydraulic tank until the lefthand differential cylinder is fully retracted.

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1


12.5 mm 12.5 mm

Overview


Phase HHigh pressure oil from the switching valve (6) has notshifted the S3 valve (3) fully to the left hand position.At this point the pressure oil to the rock valve shiftcylinder (4) is changed and the left hand side of thecylinder is getting oil so that the cylinder will retract.Oil from the right hand side of the rock valve shiftcylinder (4) is being routed to tank via valves (3, 1) andfilter (7).

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1


12.5 mm 12.5 mm

Overview


Phase IThe rock valve shift cylinder (4) has now fullyretracted. At this point a signal is sent to the right handend cap of the S2 valve (2) from a signal port on the onthe rock valve shift cylinder (4). As the S2 valve (2)shifts to the left oil from the right hand end cap of theS2 valve (2) is routed to the hydraulic tank via checkvalve (12), valves (3, 1) and filter (7).

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1


12.5 mm 12.5 mm

Overview


Phase JWith the S2 valve (2) fully shifted and held in the leftposition, pressure oil is routed through the S1 valve (1)and the S2 valve (2) to the rod side of the right handdifferential cylinder. Please note that check valve (16)must close otherwise the right hand differentialcylinder will not retract.

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1


12.5 mm 12.5 mm

Overview


Phase KRefer to diagram 1 for explanation of first workingstroke.

Overview


KEYHigh Pressure

Rocking Oil

Low Pressure


S3

1.5 mmhole drilled

through spool

S2

S1

4

5

12 13

14 15

16

17

18

6

2

3

D

To Agitator

7

8

10

20

1


12.5 mm 12.5 mm

Overview


Component Locations

For the purpose of familiarization, we will check outthe unit with a simulated walk around (Figure 10).

Right Side Components1. Main Control Panel2. Forward Neutral Reverse Handvalve3. Agitator Handvalve4. Accumulator Pressure5. Hydraulic Pump Pressure Gauge6. Pressure Gauge Shut-off Valve7. Hydraulic Temperature Gauge8. Throttle Control9. Stroke Limiter

10. Hydraulic Oil Fill Port11. Diesel Engine Oil Drain Cock12. Diesel Fuel Tank Filler13. Quarter turn blocking cock

• Item 1. Main control panel (Figure 11). Themain control panel houses the toggle thatswitches between local operation and remotecontrol operation. In addition, the main controlpanel contains the controls needed for the “local”mode. An emergency stop switch is also locatedon this main control panel.

1. F1 Fuse - Pump ON/OFF circuit.2. F2 Fuse - Blank (Spare for optional

vibrator).3. F3 Fuse - Fuel shut-off circuit and

Emergency Stop Switches.4. F4 Fuse - Agitator Bypass Circuit.5. Emergency Stop Switch - Pushing this

switch shuts off the engine and dumps allhydraulic oil circuits to the reservoir, therebypreventing machine movement.6. Hour meter - Records the number of hours

the engine runs. An in-line fuse for the hourmeter is located inside the control panel.

SWG98n149.eps

13Figure 10

Numbers show the locations of items on the right-side of the unit

Overview


7. Oil Pressure Indicator Light - Thisindicates NO oil pressure or DANGEROUSLYLOW oil pressure.8. Alternator Indicator Light - This indicates

the alternator is not charging.9. Coolant Level Indicator Light - Indicates

the radiator coolant level is low (Found on WPunits only). 10. Remote Cable Connection - Remotecontrol cable or dummy plug must beconnected here.11. Ignition Switch - Starts the diesel engine.

12. Tachometer - Measures the RPM of theinput shaft of the hydraulic pump.13. WP and SP 1000 panel, Pump Switch -Select PUMP Forward / Off / Reverse. Switchwill only function with the Local / Remoteswitch in the Local position.

BPA panel, Hydraulic oil cooler, fanswitch.14. Local / Remote switch - Select Localoperation or Remote operation. Switch alsoenables concrete pump On / Off between Localposition and Neutral.

Hours(Horas)

RPM

F1 F2 F3 F4

+-

30392976 C DUMMY PLUG OR REMOTE MUST BE PLUGGED IN TO OPERATE.

0

10

20

30

40

RPM

X 1000

Hobbs

I

QUARTZ

0 0 0 0 0 0

HOURS

1

7

10

11

12

13

14

8 9

2 3 4 5 6

WP or 2000 main control panel

Hours

RPM

DUMMY PLUG OR REMOTE MUST BE PLUGGED IN TO OPERATE.

F1 F2 F3 F4

+-

30329773 G

Hobbs

I

QUARTZ

0 0 0 0 0 0

HOURS

1

7

10

11

12

13

14

8

2 3 4 5 6

0

10

20

30

40

RPM

X 1000

BPA main control panel

Blown Fuse Indicators

Concrete PumpBomba de Concreto

Forward/ReverseDelantera/Reversa

VibratorVibrador

RPMRPM

EngineMotor

AgitatorAgitador

Indicadores de Fusibles Fundidos

Preheat Coolant Fault

F1 F2 F3 F4 F5 F6

30396991

Alt. FaultPrecalentar Refrigerante FallaAlternador

SP1000 TIER 3 main control panel

DEUTZDEUTZ

1 2 3 45

11

13

14

Figure 11Components of the Main

Control panel WP unit (top left), BPA unit (top right),

and SP 1000 TIER 3 (bottom)

Overview


• Item 2. The concrete pump forward/neutral/reverse hand valve (Figure 12). This lever actu-ates the concrete pump to run in forward orreverse. Neutral may also be selected.

• Item 3. Agitator hand valve (Figure 12). Setsbetween forward rotation, neutral, and reverserotation. All positions are detented.

• Item 4. Accumulator circuit pressure gauge inmetric bars and PSI (Figure 12).

• Item 5. Concrete pump circuit pressure gaugein metric bars and PSI (Figure 12). The operating

section contains detailed information about thisgauge.

• Item 6. Concrete pump circuit pressure gaugeshut-off valve (Figure 12). Shuts off hydraulic oilpressure to pump pressure gauge.

• Item 7. Hydraulic oil temperature gauge (Fig-ure 12). Measures temperature of hydraulic oil inreservoir.

• Item 8. Engine throttle (Figure 12). Controlsdiesel engine speed.

Figure 12Right Side Controls

Overview


• Item 9. Manual Stroke limiter (Figure 13). Thisvalve controls the amount of oil put out by theconcrete pump circuit hydraulic pumps, therebycontrolling the strokes per minute of the concretepump. It is a pressure reducing valve, getting itspressure signal from the accumulator, and put-ting its reduced pressure signal output to the

main hydraulic pumps at port Y. This is the pre-ferred method of speed control for the pump inmany (but not all) cases. You should read andunderstand the section regarding speed control inthe “Operations” section of this manual.

• Item 10. Hydraulic oil fill port (Figure 14).Install only filtered oil.

Item 9 (Stroke limiter)

SWG98n152.eps

Figure 13Manual Stroke Limiter

hydfill.eps

Hydraulic fillport

Item 10

Figure 14Hydraulic oil fill port

Overview


• Item 11. Diesel engine oil drain cock (Figure15). Used to drain oil from crankcase for routineservicing.

• Item 12. Diesel fuel tank filler cap (Figure 15).

• Item 13. Quarter-turn valve (Figure 15). Thisvalve prevents shifting of the rock valve (see Fig-ure 4) and, under certain circumstances, causesthe unit to go into a high pressure state.

Towing End

• Item 14. Hand crank (Figure 16). Adjust theextension/retraction of the manual jackingdevice.

• Item 15. Air filter (Figure 16, and Figure 19).Purifies the air drawn into the diesel engine.

• Item 16. Air restriction indicator (Figure 15 andFigure 19). Indicates the amount of air restrictedto the engine caused by a dirty or plugged filter.

• Item 17. Air intake fan shroud (Figure 15, Figure16, and Figure 18) for Deutz Diesel air-cooledengines. Keep this opening clean and free ofdebris and dirt. Engine would overheat ifblocked.

fuelfill.eps

Item 11Oil drain cock

Item 17Air intakefan shroud

Item 16Air restrictionindicator

Item 12Fuel tank filler cap

13

Figure 15Oil drain cock and Diesel filler cap

Overview


• Item 18. Air cleaner for diesel engine (Figure19). This unit houses that air filter and the airrestriction indicator.

SWG98n153.eps

14

17

19

15

Figure 16Towing end of unit

1 Differential Cylinders2 Water Box3 Material Cylinders4 Pistons (also called Rams)5 Main Relief Valve6 Slewing Cylinders7 Discharge Flap8 Rock Valve Unit9 Concrete PumpForward/Neutral/Reverse Handvalve

21

3

4

5

6

7

8

9

SWG98n154.eps

Figure 17Pump kit

handcrank.eps

Hand crank

Pre-filterwater separator

Air intakefan shroud

Figure 18Hand crank, Pre-flter, and Air intake fan

shroud

Air filter

airfilter.eps

Air restrictionindicator

18

Figure 19Air Filter and air restriction

indicator

Overview


• Item 19. (Figure 16) Diesel pre-filter with waterdrain cock (Figure 20). The filter removes waterfrom the diesel fuel while the drain cock allowsany moisture to be drained. The main filter of the

Tier 3/Com3 engine is shown in Figure 21.

prefilter.eps

Figure 20Pre-Filter

7002rebotcO0001PW2 -- 11

SECTION

2DEUTZ TCD2012 ENGINE INSTALLATION(3 OF 3)

Figure 21Main filter

Overview


Left Side

23 26

27

20

2422

25

21SWG98n156.eps

Figure 22Left side of unit

• 20. Waterbox• 21. Soft Switch Circuit• 22. Tool Compartment• 23. Battery Compartment• 24. Laminated book Rack with

Safety manual holder inside door.• 25. Emergency Stop Switches (2)• 26. Diesel Fuel Tank Filler Cap

(Driver side)• 27. Radiator and coolant level

indicator (under access door)

Overview


• Item 20. The waterbox (Figure 23). This compo-nent is actually part of the pump kit. The water inthe box flushes the differential cylinder rods andthe back sides of the rubber rams, keeping themcool. You must be very careful when entering thewaterbox area, as the hydraulic cylinders thatoperate there are capable of tremendous forces.Under no circumstances should you remove thecover when the pump is operating or ready tooperate. See the warnings in the Safety Manualregarding the waterbox.

SWG98n157.eps

Figure 23Waterbox

Overview


• Item 21. Your pump is designed with a softswitch system that reduces main system pressureduring the shifting of the Rock Valve. In theevent of a failure in the soft switch system, it ispossible that your main system pumping pres-sure could be reduced to the continuous pressureof the soft switch system (100 bar). In an emer-gency, it is possible to disable the soft switchfunction by turning the soft switch shutoff valve90˚ (Figure 112).

NOTE!The stroke limiter must be turned down to60% or less before disabling the soft switchfunction to prevent damaging the hydraulicsystem.

This procedure causes an extreme pressure spike of onthe system with each stroke. Have the system repaired,and enable the soft switch as soon as possible.

0002

76.e

ps

Closed Open

Soft switch Soft switch relief cartridgerelief cartridge

Safety relief cartridgeSafety relief cartridge

Figure 24The Soft Switch Valve found on the Brain

Overview


• Item 22. The tool components (Figure 25). Thereis a storage compartment on the drivers side;however, all accessories are shipped in a crate.

5

4

3

2

1

Figure 25Supplied Accessories

The supplies accessories include the following:

1. Remote control with 30 meters of cable

2. Rock valve cover alignment bolts

3. Clean-out rake

4. Tool box complete with tools

5. Box containing parts books, operator manuals,and other literature

Overview


• Item 23. Battery Compartment (Figure 26).

Figure 26Engine Battery

Overview


• Item 24. Laminated book rack (Figure 27 top).This rack is provided for the purpose of keepingany laminated documents that must stay with themachine.Safety Manual holder (Figure 27 bottom). Thistube is designed to hold the latest Safety Manual.

quickindex.eps

safemanhldr.eps

Figure 27Safety Manual Holder

Overview


• Item 25. Emergency Stop Switch (Figure 29).Pushing this switch shuts off the engine anddumps all hydraulic oil circuits to the reservoir,thereby preventing machine movement.

Figure 28Quarter-turn Valve

Figure 29Emergency Stop Switch

Overview


• Item 26. Diesel fuel tank filler cap (Figure 22).

• Item 27. Radiator coolant level indicator. Indi-cates level of coolant in the radiator (Figure 30).

tier2indicator

Coolant indicator

Figure 30Radiator Coolant Level Indicator for WP 1250 and BPA 2000 (left) and

WP Tier 2 and 3 (right)

Overview


Hopper Area

• Item 28. The agitator motor (Figure 32). This isa hydraulic motor that is directly coupled to theagitator shaft.

SWG98n164.eps

28

29

30

31

32

Figure 31Components of the Hopper Area

Figure 32Agitator Motor

Overview


• Item 29. Rock valve grease manifold (Figure33). From this manifold, you can grease allpoints on the rock valve assembly that wouldnormally not be easily accessible to a grease gun.

There are other points on the rock valve assem-bly that must be greased, but they are in accessi-ble locations.

• Item 30. Rock valve assembly (Figure 34).Maintenance of the rock valve components arecovered in detail in Section 6 of this manual.

Here we will just note some of the external com-ponent names and locations.

Figure 33Grease Manifold

5

2

1

3

4

1 Tension Nut Locking Bolt2 Tension Nut3 Outlet Pipe4 Clean-out Cover5 Grease Zerk

SWG98n167.eps

Figure 34Components of the Rock Valve Area

Overview


• Item 31. Optional electric vibrator (Figure 35).This device is an electric motor that has eccentricweights attached to a shaft at each end. When themotor spins, the weights shake the unit, andwhatever is attached to it (the hopper grate orhopper, in our case). The purpose of this device

is to assist low slump concrete in falling throughthe grate, and into the concrete cylinders. If youruse of this machine includes pumping of lowslump concrete, you will find this option invalu-able.

• Item 32. Hopper grate interlock safety switch.Hopper grate must be completely down to closesafety switch or pump will not operate.

Figure 35Vibrator mounted on the hopper grate

WP hopper grate interlock switch BPA hopper grate interlock switch

hoppergratelock.eps

Figure 36Hopper grate interlock switch WP units (left) and BPA units (right)

Overview


Safety DevicesThe following is a separate grouping of just the safetydevices found on the pump. The items listed hereMUST be kept in good working condition, or injurymay result. Bypassing a safety device for servicing oremergency fold-up or clean-out should only be done bypersons that know what systems are disabled by thebypass procedure, and must be set back to the originalposition upon completion of the service or emergencyprocedure.

Emergency Stop SwitchesIn addition to the emergency stop switch on the maincontrol panel, there is an emergency stop switch on theopposite side of the hopper and at the top side of thewaterbox. If you are operating from the remote controlbox, you will find another emergency stop switch there.All emergency stop switches are wired in series, sothey do the exact same thing. The emergency stopswitch on the remote control box will not work if it isnot plugged in, because the remote control box iselectrically removed from the system at this time. Theemergency stop switches cut off electricity to theconcrete pump forward/reverse/pilot valve. In addition,they stop the electricity path to the normally openbypass valve (dump valve).

Automatic Shut-off Circuit AgitatorThe agitator hydraulic circuit runs through a separatedump valve that routes oil directly from the pump backto tank if the following safety conditions arecompromised:

• electricity is lost on the unit• the hopper grate is raised• the hopper grate is removed

In spite of this safety device it is important toremember that it is made of machine parts which,according to Murphy’s law, will fail at the worstpossible moment. Never put your hands, arms, legs orany other body part into the hopper while the hydraulicsystem is ready to operate.

Safety Valves (Pressure relief valves)The pressures listed on hydraulic schematics and inmanuals and literature are not nominal figures. Theyare the pressures that the machine was designed towork with, and that the components were designed toaccommodate. There are a very few instances where

pressures may be “tweaked” to accomplish certainthings, but they must only be done with the advice andstep by step instructions of an authorized Schwingrepresentative familiar with the system and safetydevices, such as a serviceman. Under no circumstancesshould you raise pressures arbitrarily, or because you“think it might help”. Conversely, lowering pressuresettings may cause poor machine performance, heatand its related premature component degradation, andin some extreme cases, could cause dangerousoperation.

Safety GuardsIn addition to the aforementioned safety devices, thereare guards placed over moving parts. Following is a listof the guards:

• waterbox grate and covers• hopper grate• slewing cylinder cover

These were placed for YOUR protection. Don’t operatethe machine without all safety guards in place. If theybecome damaged, lost, stolen or inoperable because ofany other circumstances, they must be replaced beforeoperation continues.

FusesFuses are devices that are intended to protect againstcomplete system failure, fire, and dangerous operation.They do so by melting when the current in an electricalcircuit becomes higher than it is allowed to get. Hereare a couple of examples of causes of over current:

• Short circuits (positive goes to negativewithout resistance).

• Component malfunction (a coil that has tomove a sticky valve).

• Mechanical interference (a shovel handle stuckthrough the oil cooler fan blade).

In order to maintain this safety device, you simplyreplace a blown fuse with the correct size and typefuse, and NEVER bypass a fuse. A very good rule ofthumb for fuses is this: If it blows once, replace it. If itblows again, there is something very wrong. Find thecause of the problem and repair it before activating thecircuit again.

Overview


Warning LabelsEach machine is equipped with a set of warning labels(Figure 38, 39, and 40) that are installed based onmodel and installed options. These labels will fade intime from ultraviolet radiation, rain, steam cleaning,etc. It is very important that the machine has acomplete and readable set of the warning labels at alltimes. To address the problem of fading labels,Schwing has made the decision to supply warninglabels without charge for as long as the machine is inservice. To get replacement labels, identify whichlabel(s) you need from the following diagrams andlists, get the serial number of the unit off the serialnumber plate and call our Spare Parts Department at 1(800) 237-8960. The person taking the order will makea note of the serial number of the unit for our files, andsend you the labels that you need. Complete sets orsingle labels may be ordered. If the serial number plateis missing or unreadable, the number is stamped intothe subframe just below the normal location of theserial number plate.

Overview


20

43

48

45

45

44

46

4347

48

44

46

20

Figure 37Decal Locations for WP 1000

Overview


ROCK VALVE™

1

4

7

10 11 12

13 1415

5 6

2 3

WARNING

Do not stand on hopper grates.

SAFETY

MANUAL

WARNINGDo not operate this machine without training. Understand the warnings in safety manuals and on decals.

You can order additional operation manuals, spare parts books, safety manuals and decal sets by contacting us at:

Schwing America, Inc. - Small Line Division1-(888)-535-4105

8:00 AM to 5:00 PM Eastern TimeMonday through Friday

30333268 B

IMPORTANTWARNING

CONCRETE PUMP

8 9

ACCUMULATOR

THROTTLE

WP 1000X

This machine is remote controlled and may start at any time. Stop engine before servicing unit.

WARNING

30309999 C

WARNING

Clear area before activating outriggers

30337012

TEXACO

Factory-filled with

Rando HDZP/N 30345427

TEXACO

Factory-filled with

Rando HDP/N 30345426

Figure 38Warning Labels

Overview


Keep hands out of waterbox.Stop engine/motor if access is required. Keep guards in place.

30319872 D

WARNING

This product is covered by one or more of the following U.S. patents:3,409,3343,580,6963,640,3033,685,5433,741,6913,829,2514,019,839

4,057,3734,178,1424,191,5134,260,3384,343,5984,373,2254,373,875

4,392,5104,437,8174,465,4414,472,1184,556,3704,621,3754,681,022

4,708,2884,852,4674,978,0735,066,2035,106,2255,106,2725,224,654

5,257,9125,263,8285,281,1135,332,3665,346,3685,401,140

Re. 32,041Re. 32,657Re. 32,719

16

19 20

28 29 30

21

22 23 24

25 26 27

17 18

WARNINGBefore opening a blocked pipeline, relieve pressure by making 2 reverse strokes.

WARNING

Keep hands out of hopper and valve assembly. See operation manual if access is required.

FORWARD/NEUTRAL/REVERSE

30312146 A

SAFETY INSTRUCTIONS1. Operation of this machine requires training. You must read all warning labels on the unit -

items covered on specific warning labels are not covered here. There are other hazards and safety rules that are ONLY covered in the safety manual or operation manual.

2. Only the operator may authorize access to the unit or surrounding area.

3. Safety devices and guards must NOT be altered or removed.

4. Stop the operation if any malfunctions, failures or structural faults occur. DO NOT restart until repaired.

5. Keep the control devices in good working condition. Do not attempt to complete a job with safety devices bypassed.

6. You must always be able to see the point of discharge. If this is impossible, an assistant (spotter) MUST be used. The spotter must be positioned to see both the operator and point of discharge for the purpose of giving instructions to the operator.

7. Maintain a safe distance from excavations or cliffs. The trailer weight increases significantly when concrete is placed in the hopper.

8. Any and all clamps, hoses and pipe connected to the unit MUST be able to withstand the maximum concrete pressure of the unit.

9. Be sure outriggers are retracted and pinned before driving the unit.

10. Cleaning a separately laid pipeline with compressed air should only be done under the supervision of an expert. All hoses must be removed, and a ball catcher MUST be attached to the discharge.

11. Wear a hardhat, safety goggles, ear protection, gloves, steel toed shoes and tight fitting clothes when working on or near a concrete pump.

12. Never leave the unit unattended when it is running or ready to operate, especially around children. Disable the remote control before setting it down.

13. When there is concrete in the hopper, do not tow faster than 5 MPH or travel on any public roadway for the following reasons:

• Concrete in the hopper changes the weight distribution, making the tongue end too light (this causes “fishtailing”).

• It may overload the axles.

• Concrete may splash out of the hopper, causing a road hazard for other vehicles.

SAFETY INSTRUCTIONSBEFORE REMOVING HOPPER GRATE ORPERFORMING ANY SERVICE:

1. Stop the engine.

2. Remove the key, place it in your pocket, and put a "DO NOT OPERATE" tag on the switch.

3. Check accumulator circuit pressure gauge (if so equipped) to verify zero system pressure.

1. Stop the electric motor.

2. Lock out the power source according to an approved lockout-tagout program.

3. Check accumulator circuit pressure gauge (if so equipped) to verify zero system pressure.

Gasoline or Diesel Engines Electric Motors WARNINGStored hydraulic energy. Release all hydraulic pressure and verify zero pressure on gauge before servicing.

IMPORTANT

DATE OF LAST CHANGE DATE OF LAST CHANGE DATE OF LAST CHANGE

Change all filter elements if the dirty filter lamp illuminates when oil is above 20 C. If unit does not have electrical filter lamp, change the filter elements every 13,000 yds or every 6 months, whichever occurs first.

EMERGENCY STOP

PAR

O D

E EM

ERGENCIA ARRÉT D'U

RGE

NC

E

DIESEL ONLY

SAFETY INSTRUCTIONSAccumulator Safety Rules1. Never assume that the system is relieved of oil pressure.2. Always relieve the hydraulic system of pressure before dis-assembly for clean out, repair, or maintenance.3. Check accumulator circuit pressure gauge to verify zero system pressure.4. Never assume that it is safe to put your hands in the concrete valve.5. Stopping the engine does not guarantee zero system pressure.6. Stopping the concrete pump electrically does not de-pressurize the accumulator circuit.7. NEVER use oxygen or compressed air to charge the accumulator!8. Operation of the machine without the correct nitrogen pressure could damage the accumulator. Before charging the accumulator, understand the procedure. Read the operation manual.

(2 taps)

CPMA0038

6.ADD WATER4-GALLONS

7.ALL DONECLEAN UP

5.RELIEVE

PRESSURE

4.LITTLE BIT

3.STOP PUMP

2.SLOW PUMP

DOWN

1.START PUMP

SPEED UP

WARNING

Keep hands out of concrete valve. See operation manual if accessis required.

30363739

Figure 39Warning Labels (cont.)

Overview


32

34

34

34 34

35

38

41 42

39

40

36

37

33 34

WARNINGExplosion hazard. Do not charge accumulator with oxygen or compressed air. Charge with dry nitrogen only.

PARTS AND OPERATION

MANUAL

WARNINGSafety guard is missing.

30337004 A

Do not operate.

Men working on

equipment.

No operar.

Personal trabajando

en el equipo.

30332963

WARNING CUIDADO

Do not operate at pressures exceeding the rating of the entire material delivery system.

30306123 D

WARNING

30355887

WARNING Failure to follow these instructions for Dexter

axles may result in wheel breakage or wheel loss. These problems can cause injury or death! Tighten flange nuts to 275-325 lb.-ft. or as shown on nuts before first road use. Retighten at 50 miles and 100 miles. Check periodically thereafter.

30350290


Overview


43

46 47 48

44 45

WARNING

Stand clear of outriggers when activating.

30364520

WARNINGBurn hazard. Do not touch hot engine or exhaust parts.

30364523

Do not insert solid objects into waterbox cleanout holes.

WARNING

30355137

NO!

Stop agitator before putting any solid object in hopper.

WARNING

30354742A

WARNING

Do NOT bring the remote control near the waterbox when changing rams.See manual.

30363822

1. Use only matching pintal hitch.2. Use breakaway cable and both safety chains when

towing this unit.3. Inspect and test actuator and brakes before towing this

unit.4. Towing vehicle and hitch must be rated to tow:

(xxxx) 30319923 B

SAFETY INSTRUCTIONS

Maximum GrossTrailer Weight

xxxx pounds

MaximumVertical Load

xxxx pounds

WARNINGRunaway trailer hazard. Obey Safety Instructions.


Operation

Line pumpsStartup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve models:Frame files:operation.fm Operation Manual - 97

OPERATIONPreparation ............................................................................................... 98Towing the unit........................................................................................ 102Unit Set-Up ............................................................................................. 103Operating the Pump................................................................................ 104Special Pumping Situations .................................................................... 123

swg99a001.eps

Operation


Operation

PreparationBefore you pump the first job with this machine, youmust know what you are doing. If you have neverpumped concrete before, become familiar with thisentire manual, the safety rules for pumping concrete asdescribed in the Schwing Safety Manual (included asSection 3 of this manual), the features of the machine,and the procedures for pumping concrete. It would be avery good idea to set up the machine in a safe locationand practice with the pump controls before you everput concrete in the machine. Once you are on a job sitewith the machine, you will have the safety of manyother people in your hands and it will be inappropriateand unsafe to make mistakes. Only experience inrunning the unit will give you the confidence and finecontrol that your coworkers expect and deserve.

If you are an experienced pump operator already, readthis manual cover to cover anyway, to be sure youunderstand the particulars of your new machine. Set upthe unit for a trial run before you take it to a job. Youwill not regret knowing the location of the controls anddevices.

This manual will discuss specific setup, cleanout,maintenance, and operation techniques ONLY as theyrelate to this particular machine. It is not the intentionof this manual to teach you how to be an expertconcrete pump operator. For that, you will need theinformation from this manual, plus information fromseveral other sources (listed under the heading of“Additional Reading Material” in the Appendix sectionof this manual, starting on page 7-40) and extensive onthe job experience.

Arrive to work on time, with a clear head.A professional pump operator knows that the day willgo better if you have time to do the pre-checks outlinedin the following paragraphs. If you skip them becauseyou are late for work, you are setting yourself up for atleast a bad day, and perhaps an accident. Wanderingaround the shop in a stupor because of a hangover orlack of sleep is no better than showing up late. Eitherway, you will not be certain that the machine is in tiptop shape and all necessary equipment and accessoriesare present and in good working order until it’s too lateto do anything about it.

Have the right machine for the job.Concrete pumps are limited in what jobs they can do.Be sure you have the appropriate pump for yourparticular job. Schwing’s Sales and ServiceDepartment can assist you with pump applicationquestions.

Have the equipment that you will need for the job.Will you need extra pipe sections to make the pour?Use the following checklist for pipeline needs:

• Pipe sections• Adapter pipes, if all pipe ends are not identical

(see the pipe end comparison in the Appendixsection of this manual, beginning on page7-32).

• End hoses• Reducers• Clamps for all pipe end styles and sizes• Clamp Pins

Have all pipe and pipe accessories inspected forcondition, loaded, and secured for travel before movingthe unit. Keep in mind the pressure rating of your unitwhen you inspect the condition of pipe accessories -see the chart regarding pipewall thickness versuspressure in the Appendix section of this manual,beginning on page 7-33.

You will also need normal everyday pumpingaccessories. Use the following list as a minimum fornormal pumping requirements:

• Shovel• Barrel for mixing slurry, if required. It is

recommended that the barrel remain with theunit if you ever use it, even if you don’t need itfor today’s job.

• Pipeline lubrication mixes, enough for theday’s job. Either commercial lubricatingpowder or portland cement for mixing slurry.NOTE! This is not always required, in somecases slurry will be delivered to you, in othercases the portland cement will be supplied atthe job site. In all cases, you must know howyour lubrication will be accomplished beforeyou leave the yard.

• Grease gun and grease tubes

Operation


• Spray can filled with form oil (not necessary,but very helpful)

• Clean-out balls• Water hose and nozzle• Clean-out rake• Working lamps for night work• An approved air blow-out cap (see the Safety

Manual for blow out cap requirements)• 5 gallon bucket• Hand tools• Hammer

Of all of the above mentioned items, the hammer is thetool that you will need the most often. It can be usedfor pipeline setup and removal. It can be used to tappipe to locate blockages (follow the safety instructionsfound in the Safety Manual portion of this OperationManual for this procedure). It makes a good persuasiondevice for rusted nuts and bolts, and for knocking outconcrete that has set up in clamps and hoppers. Manypumpers take the head off of the wooden handle andhave it installed on a steel pipe. This makes it perfectfor pipeline installation, because the handle can beused to pry clamp handles up or down. Experiencedpump operators never walk from the pump to thepipeline without a hammer. A four or five pound sledgeworks best.

Last, but not least, you will need the things requiredby law for operation of a motor vehicle, things relatedto safety of the motor vehicle, and paperwork neededfor the job, such as:

• Valid driver’s license• Fuel permit• Cab card• Registration• Insurance card• First aid kit• Flares• Reflector signs• Fire extinguisher• Job ticket• Map(s)• Job site phone number and contact person

Operation


Have the right personal protective equipment for the job.

• Concrete is made from lime, which is veryalkaline. If it stays on your skin long enough, itwill cause severe burns, and in extreme casesthe affected skin will simply fall off. Becauseof this, always wear water resistant work bootsand gloves, and if you will be working IN theconcrete, wear water PROOF gloves and boots.In either case, the boots should have steel toes.There are boots made especially for concretework that will protect your feet from lime andaccidental impact (Figure 42).

• Falling objects on a job site are notuncommon. Hard hats were made to protectyou from this hazard, but they only work if youwear them.

• Safety goggles may very well keep you fromgetting splashed concrete in your eyes.

• Snug fitting work clothes will help preventaccidents involving moving parts.

• Concrete pumps may generate higher soundpressure levels than O.S.H.A. allows forconstant exposure. You can protect yourself bywearing hearing protection when on or nearthe machine.

• When mixing your grout in the morning, oranytime that there will be airborne cement orother fine powder nearby, wear breathingprotection.

• Anytime that there is danger of ricochetedrocks or sand (when shotcreting, for example),wear a full face shield.

SafegearWvest.eps

SAFETYGOGGLES

BREATHINGMASK

SAFETYVEST

SNUGFITTING

CLOTHES

GLOVES

STEEL TOEDSHOES

HARD HAT

HEARINGPROTECTION

Figure 42Wear personal protective equipment

Operation


Check the equipment before leaving the yard.Check the following items each day before the pump istaken from the yard. It is easier to remedy a problem inthe yard then at a work site.

On The Towing Truck• Truck engine oil level and condition.• Antifreeze / coolant level in the radiator.• Battery fluid level and condition.• Tire condition and proper air pressure.• Brake system air pressure and condition (bleed

water from air tanks).• Clean the windows of ice, frost, mud, etc.• Clean the mirrors of ice, frost and mud, and

properly align for clear vision.• Keep the cab free of debris, especially on the

floor. Accidents can happen when foreignobjects get stuck between the clutch or brakepedal and the fire wall.

On The Pump • Check diesel fuel level in all tanks.• Verify diesel engine oil level.• Radiator coolant level should be full.• Check that battery and battery cable

connections are clean and tight.• Check condition of belts and hoses. Replace as

necessary.• Verify all safety guards are in place.• Grease Agitator bearings.• Grease Rock Valve lubrication points.• Clean any dirt or debris from engine air intake.• Check condition of tires and air pressure.• Structural integrity of the unit. Give the unit a

visual inspection. Look for cracks, chippedpaint, rust (especially rust under the paint), andmissing parts. Clean and repaint areas thathave chipped paint to avoid damage tostructural steel. Replace missing parts beforeusing the unit. Report any structuralabnormalities to the Schwing EngineeringDepartment before using the unit. If theengineers determine that repair is necessary forsafe operation, DO NOT OPERATE THEUNIT UNTIL REPAIRS ARE COMPLETED.

Pipeline must be complete and free of dents,cracks and holes. Pipe must have sufficientwall thickness to handle the maximumpressure of the pump. (Inspect weekly with anultrasonic thickness tester. See Maintenancesection of this manual, beginning on page6-10.) All safety guards must be in place andsecure for travel.

• Hydraulic oil level and condition. The oilshould be clear and clean looking. ‘Milky’looking oil, or oil with a lot of air bubblesentrained is oil that needs replacement beforethe next job begins. (NOTE! Oil that isholding air bubbles overnight should bereplaced, but it is not an oil problem if it isbecoming bubbly on the job. In that cases, itwill be a problem with the integrity of thehydraulic seals somewhere in the system.) Topup oil levels ONLY with the same type of oilthat is in the reservoir. Do not mix namebrands, even if they have the same viscosity.Each oil manufacturer uses different additivepackages to accomplish anti-foaming, siltsettling, anti-wear, etc. The mixing of thesedifferent chemical additive packages mayrender them useless.

• Drain water from the hydraulic reservoir eachmorning. This is done by removing the pipeplug and opening the drain valve located underthe hydraulic reservoir, and allowing the fluidto run into a pan until it changes from water tooil. (Water is heavier than oil, so it sits on thebottom of the tank, and therefore drains outfirst.)

• Visually check the unit for hydraulic leaks, andrepair any leaks before operating the machine.Lost hydraulic oil harms the environment, andit is expensive to clean up and replace the lostoil.

• Be sure that everything on the unit is ready forroad travel. This includes securing allaccessories and miscellaneous equipment.

Operation


Towing the unitMany accidents involving concrete pumps are trafficaccidents. To avoid accidents, you must remember thisone point...you are not driving a car. You know thoseyellow caution signs posted on the roads? The ones thatsay 50 M.P.H. under the symbol for a curve in theroad? Those signs are meant for you, when you aretowing a pump. Most people ignore those signs whenthey are in their car, because the car they drive feelssafe going around that curve at 60 M.P.H. When towinga trailer-mounted concrete pump, this is NOT the case.All caution signs will apply to you when you aretowing a pump. Slippery when wet, bridge out ahead,and all the rest. Trailer-mounted concrete pumps areheavy, which results in longer stopping distances. Theyare top heavy, which can lead to rollovers at speeds thatwould be no problem for a car. You can’t see directlybehind you, so backing up becomes dangerous, etc.You know the rules of the road for trucks, or youwouldn’t have passed the commercial driver’s licenseexam. This section of the manual deals with thespecifics that they can’t include in the driver’smanual...the way a trailer-mounted concrete pump actsunder various driving conditions.

Licensing.If you don’t have a valid commercial driver’s license,DO NOT TOW THIS UNIT.

Backing up.You will be able to see the road behind you on the leftand right sides, but YOU WILL NOT BE ABLE TOSEE DIRECTLY BEHIND YOU. If you must back up,and there is any chance at all that there may be trafficor pedestrians behind you, you must use a guide. Aguide is a person that watches for traffic, pedestrians,and other obstructions, and stands in such a positionthat you can see him (her) giving you instructions.Installing a back up warning device such as a horn orbell will give you some measure of safety, but youcan’t rely on it. For example, a child walking behindyour unit when you begin to back up may becomefrightened by the back up warning sound and freezewhere they stand.

If you are in an isolated area where there will not betraffic or pedestrians, you can get out of the cab andlook for obstructions before beginning to back up.

Changing lanes.When towing a pump, you will have blind spots to yourright and left sides. Unfortunately, many drivers areunaware of these spots, and will travel in them forextended time periods. These spots are avoidable withthe use of convex mirrors, which attach on or below therear view mirrors. Before changing lanes, check theseconvex mirrors for other drivers who may be ‘hiding’there. Signaling well in advance will warn other driversof your intentions.

Loading the unit for shipment.If the unit will be transported (such as by railroad orship), care must be taken to see that people andproperty are protected during the loading process. Inthese cases, remember the following points:

For Ramp Loading• Use only ramps that provide adequate and

stable support for loading purposes. Ensurethat no one would be hurt if the unit were to tipor slip off of the ramps.

• Be sure that the ramps will not cause the unitto pivot beyond the ability of the hitch.

• If you are using guides to provide instructions,they must not remain in the driving zone.

• Secure the machine on the transport vehicleagainst rolling, slipping or tipping over.

For Crane Or Forklift Loading/unloading• If lifting the unit with a forklift, be sure that the

forks do not damage any components that sitbelow the bottom of the subframe.

• Concrete pumps may only be moved by craneif they have been equipped with slinging ringsthat were designed for that purpose. Slingingrings that were designed for this purpose canbe ordered from Schwing for installation onnew units, or for field retrofits.

• Never hook lifting devices to standard pumpparts, like the concrete valve, hopper, oranything else. These parts were definitely NOTdesigned to support the entire unit load.

• Check the load bearing capacity of any slings,cables or other lifting devices that will be usedto lift the machine. Never exceed the ratedworking capacity of the lifting device.

Operation


• No one is allowed to walk, stand, or workunder suspended loads. Keep the area free ofpersonnel.

Unit Set-Up

Selecting the proper set up location on the job site.Sometimes, the person in charge of the pour will have aspot ready for you. If he is experienced, he will pick anappropriate spot that will allow a safe and efficientpour. Other times, the person in charge will only tellyou what is to be poured, and it will be up to you toselect the set-up location. In still other cases, theperson in charge will have picked a totallyinappropriate spot for you. In these cases, your abilityto be an effective diplomat may dictate how the day isgoing to go for you. If it is not already so, you will haveto make the location safe and efficient on your own. Inall cases, the set-up point MUST allow at least oneready-mix truck to get safely to and from your hopper.

In addition to the above mentioned requirements, it isdesirable that the set-up point also have these features:

• Able to handle the safe arrival and departure of2 or more ready-mix trucks.

• Out of the way of major traffic flow patternsfor the job site. If no one can move on the sitebecause of your setup position, you will haveto move anyway...you might as well plan for itat the start.

Laying out the pipelineWe will not cover the do’s and don’ts of pipeline layoutin this manual. If you don’t know how to correctly layout a pipeline, read and understand the chapters onconcrete pipeline in one of the books about pumpingconcrete. Several of these books are listed under theheading “Additional Reading Material”, found on page7-42 in the Appendix section of this manual. We will,however, cover of few specific points that are commonto pumping jobs in North America.

Start at the point of discharge and work your way backto the pump. In the majority of cases, you will needrubber hose at the point of discharge, and usually theplacing crew will prefer 3" or 4" rubber hose to 5".This means that you will need a reducer at thedischarge end.

If you will have to reduce to smaller diameter pipe orhose for the placing crew, always make the long part ofthe run with the larger diameter, and reduce as close aspossible to the point of discharge. There is one instancewhere it may be desirable to run the entire distancewith the smaller size, and that is if you will be pumpingvery, very slowly on a hot day. In that case, theconcrete may start to set before it reaches the point ofdischarge, and it will resist the change of size that isrequired inside of a reducer. If you suspect that youmay have a job like this booked, call the SchwingService Department for advice before you set up thejob.

Use as few hoses as possible. Hoses have moreresistance to flow than pipe does, therefore it will takehigher pressure to push through hoses than pipe.

Use the largest diameter hose that the crew will let youuse. The diameter of the hose directly affects thelargest size stone that you will be able to pump. If youwill be pumping stone larger than 1", you will not beable to use 3" or smaller hose. To attempt to do so willresult in blockages.

Do not use hose for changing pipeline direction. Pipeelbows are available with many different degrees ofbend, and they will require less pumping pressure thanhose.

Setting the Stabilizers • a.Position the dunnage pads (use scrap

plywood, 2x4’s, etc.) on the ground where thestabilizer will be positioned after extension.

• bDrop each stabilizer to its pad and insert thelocking pin.

Operation


Operating the Pump• Connect the remote control cable or dummy

plug into the control panel. NOTE: The pumpwill not function without one of these pluggedin.

• Turn the Pump Switches to the OFF position.• Place Pump shift lever into the NEUTRAL

position.• Make sure all Emergency Switches are in the

RUN positions.• Insert key into ignition and turn clockwise.• Release key when engine starts.

NOTE!95% of our pumps have Turbo-ChargedDiesel engines. To avoid damage to the turbowhen starting, do not run the engine to highspeed immediately from a cold start.Bearing damage will result due toinsufficient lube oil supply. Let the enginewarm up for at least 30 seconds before goingto full speed. Failure can also occur whenshutting down the engine under full load.The oil in the supply tube can burn and plugthe line. Let the engine idle for 2 minutesbefore shutdown.

• Set throttle to 1800 RPM’s. (2500 RPMMaximum)

CAUTION! If OIL LIGHT comes onimmediately shut off engine!Do not operate until situation is corrected.

CAUTION! If ALT LIGHT comes onimmediately shut off engine!Do not operate until situation is corrected.

CAUTION! If COOLANT LEVEL LIGHTcomes on immediately shut off engine! Do not operateuntil situation is corrected.

Basic TroubleshootingEngine won’t start:

No fuel.

Emergency stop switch in OFF position.

Dead battery.Engine running but pump won’t operate:

Turn stroke limiter knob out fully.

Verify hopper grate is completely down and safety switch is activated.

Check F1 fuse for pump circuit.Engine quit running:

Check diesel fuel level.

Check F3 fuse for fuel shut-off / E-stop switch circuit.Agitator won’t operate:

Check F4 fuse for agitator bypass circuit.Hourmeter not operating:

Check hourmeter fuse inside control box.Dead Battery

Possible problem with the alternator indicator light connection or bulb on the control panel.

When the key switch is turned clockwise one click, the indicator light for the alternator (found on control panel) will illuminate and will not go out until the engine starts.

If the light does not come on when the key is turned one click clockwise, the engine may not charge the battery. The first step should to be to check the bulb. If the bulb is bad, be sure to replace it with the same size bulb. The second step would be to check the connection and receptacle internally and externally. Look for green evidence of corrosion.

Remember that the only time the bulb is illuminated is when engine is off with the key switch on. If the light does not go out after the engine starts the alternator has a fault.

If corrosion exists, the receptacle should be replaced. When the circuit is not able to be completed properly as a result of corrosion the alternator is not receiving a signal and the engine may not charge the battery when started.

If an oversized light bulb is used during replacement, the alternator may overcharge the battery causing premature battery failure.

NOTE!All new equipment comes a spare bulbinside the control panel

Operation


Before the first truck backs up to your hopperIf you have completed setup before the first ready mixtruck is due to arrive on the job (a highly recommendedpractice), this is a good time to get some things readyfor the day.

• Find out who will be giving you signalsthroughout the day. There must be only oneperson that gives you signals, so as to avoidconflicts in instructions. Talk to the personabout the signals that you will use, and come toan agreement before you start pumping. TheAmerican Concrete Pumping Association hasstandardized hand signals for concretepumping that are shown on decals on the unit.This decal is also shown in the Appendixsection of the Safety Manual, which isincluded as one chapter of this OperationManual. In many cases, the job sitemanagement will give you a walkie-talkie thatis on their own frequency so that you mayspeak directly to your signal man. Be awarethat in some cases, this walkie-talkie maycause interference with the Schwing radioremote control system. Check it out before thepour begins.

• Talk to the foreman of the placing crew. Besure that the crew is aware of the safety rulesfor the placing crew as described in the SafetyManual. If they are not familiar with the rules,show them the rules that apply to them fromthe quick index that was supplied with yourunit. Make sure they understand about notkinking the tip hose.

• Go over the safety rules with any oilers orlaborers that have been assigned to work withyou at the pump. Show them the emergencystop switches. If they will be backing ready-mix trucks to your hopper, explain about thedanger of putting themselves between thepump and the ready-mix truck.

• Position your remote box and cable in a placethat you won’t trip over the cable, but you willbe able to move around at will once the pourbegins. It is critical to be able to see the pointof discharge once the pour begins. If this is notpossible, arrange for a spotter NOW.

• Get your breathing mask ready for mixing theslurry. Have all of your personal protectivedevices on or nearby.

• Fill your waterbox with water, if it is notalready full (Figure 43).

• Put a couple of shovelfuls of sand or dirt in thebottom of the rock valve housing, above theclean-out door. This will prevent concrete fromfilling the door area and setting during thecourse of the day. (Figure 44).

• Be sure the clean-out door is closed tightly andlocked by tapping on the end of the “T” handlewith your hammer (Figure 45).

NOTE!THE PUMP MUST BE SHUT OFF ANYTIMEYOU REMOVE THE WATERBOX COVER ORGRATE. Secure the controls so that no onecan turn it on without your knowledge.

Figure 43Be sure the waterbox is full of water

Operation


Figure 44Put a couple of shovelfuls of sand in the

bottom of the hopper, over the clean-out door.

closedoor.eps

Figure 45Tapping on “T” handle to lock the

clean out door

Operation


• If you will be using portland cement and waterto make your lubricating slurry, prepare for itnow (Figure 46). Position your barrel, shovel,and sack of portland cement on the groundbehind your hopper. Fill your barrel with about25 or 30 gallons of water. (Of course, this stepcan be skipped if slurry is to be delivered toyou from the ready mix company, or if you areusing powdered slurry mix.)

• Get your clean-out rake in a position that youwill not trip on it, but you will be able to grab itwhen you begin clean-out. Many times,cleaning the pump is done when you are in ahurry, because concrete is setting, that is notime to have to look for the rake or, worse yet,to use your hands to pull loose material out ofthe pump because you don’t have time to lookfor it.

NOTE!NEVER use your hands for a clean-outrake.

WARNING

Amputation hazard. Stop pump before cleaning the Rock Valve and hopper.

0000

15.e

ps

Figure 46Spray 25 to 30 gallons of water

into the barrel

Operation


Grease your agitator bearings (Figure 47). There is onezerk on each side of the hopper. Re-grease every two orthree hours, as the pour allows.

NOTE!You don’t grease agitator bearings like yougrease most other bearings. That is, if younormally pump in grease until you see itsquirting out somewhere, you will ruin youragitator seals. When you grease the agitatorbearings, watch the rubber grease conesthat are located inside the hopper. You wantthe cones to bulge out slightly because theyare full of grease, but you don’t want to havethe grease come out around the shaft,

because where the grease comes outconcrete will be able to go in. Once concretemakes it inside of the grease cone, you willquickly wear out the bearings. Whenre-greasing after the hopper is full ofconcrete and you can no longer see thecones, just give the zerks a couple of squirts.This is one of the few times when it is betterto under grease than to over grease.

Grease the rock valve lubrication points before thepour begins (Figure 47). Once started, grease themevery couple of hours. There are 4 zerks to grease forthe rock valve, plus the two for the agitator.

You can keep your hopper and splash guard lookingbetter, and help yourself at clean-out time by sprayingthem with form oil before the pour begins. This oil isspecifically formulated to prevent concrete fromsticking to forms, and it works just as well atpreventing concrete from sticking to your unit. Itdoesn’t hurt to spray it on the other areas that are likelyto get splashed by concrete, either.

Figure 47Showing the location of 4 rock valve greasing joints, and

the 2 agitator grease points

Operation


Lubricate your pipeline.Once the ready mix truck(s) arrive on the job, you canlubricate your pipeline. Schwing highly recommendsthat you pre-lubricate the separately laid pipeline eachtime you must pump into dry pipe. In some parts of theUnited States and Canada, the concrete is so rich withcement fines that operators do not pre-lubricate tobegin pumping operations. This practice is NOTrecommended. The amount of time saved by notpre-lubricating cannot begin to make up for the hassleof having to remove pipe sections from a separatelylaid pipeline. Most importantly, the blockages causedby failure to lubricate can be dangerous (see the sectionon blockages in the Safety Manual section of thisOperation Manual).

There are commercially available products that willlubricate a pipeline with much less volume (meaningmuch less weight) than portland cement and water.These products usually come in sandwich sized plasticbags, and lubricate about 100 feet of 5" pipe per bag.Instructions for mixing vary by the differentmanufacturers. These products are less expensive thanportland cement, and do not set like cement. If you usethese products, pay close attention to the instructionsand warnings on the package.

If you only have portland cement for lubricating yourpipeline, you will have to wrestle with the weight.Choose one of the methods shown below, based on thejob situation. Before you begin to mix the slurry, put onyour breathing mask and the rest of your personalprotection equipment.

If you have help in the form of a laborer assigned towork at the pump, or an oiler or other handy guy, youcan mix the best slurry in a barrel. By mixing it on theground in a barrel, you can get good consistency andbreak up clumps of cement that tend to form, not unlikelumps in mashed potatoes. However, this method hasthe disadvantage of having to lift the barrel and pourthe slurry into the hopper, which is why you will needhelp. To use this method, lay a sack of portland on topof the barrel which has been filled with about 25gallons of water. Take a shovel and break open the sackwith the blade, allowing the cement to fall into thebarrel. When the bag is empty, set it off to the side andmix the cement and water with the shovel blade. Breakup any cement clumps that are encountered andcontinue mixing until the mixture is smooth andcreamy. Get your helper and pour the mixture into thehopper. It will not cover the openings to the material

cylinders, but for now, don’t worry about it. Make onebarrel of mix for each 100 feet of laid pipeline that theconcrete will see, but if you will be going through morethan 200 feet of pipe, you, your boss, or the concretesuperintendent on the job site should have arranged tohave a grout mixture brought to you by the ready mixplant. Unless you have at least a half a yard of slurrydelivered to the pump, do not try to pump this mix yet.Using the barrel method, you can add a little sand, ifneeded, to stretch the amount of slurry mixed. Thiswould be helpful if you have to pump through 300 feetof line, but only have 2 sacks of cement available.

If you are alone at the pump, you will not be able to liftthe barrel to pour the slurry into the hopper (it willweigh 250 to 300 pounds...not many people would beable to lift it alone). In this case, lay the sack of cementon the hopper grate, and break it open.

NOTE!Do not stand on the hopper grate for this, orany other, procedure. The “NO POINTRULE” applies to the hopper grate.

Get a water hose and direct the spray into the hopper,aiming at the edge of the pile of cement. This will washthe cement into the bottom of the valve housing,mixing as you go. Try to break up clumps of cementwith the spray, but do not put your hands or any otherbody part into the hopper. Mix more slurry as neededfor the length of the pipeline, as described above.When the cement has all been washed to the bottom,you can cycle the rock valve back and forth a few timesto agitate the mix a little more. Do not try to pump thismix until you can back it up with concreteimmediately.

NOTE!When initially starting the pump, or whenrestarting for any reason, personnel shouldstay a reasonable and prudent distancebeyond the reach of the discharge hose untilthe concrete runs steadily and the line is freeof compressed air. Air will be in the linewhen first starting, restarting, or after theline has been taken apart or opened for anyreason. Compressed air can cause the hoseto whip violently. For more detailedinformation see the Safety Manual.

Operation


Figure 48Mixing the slurry in a barrel

Operation


After the correct amount of slurry has been placed inthe hopper, back up the first ready mix truck to yourhopper.

NOTE!DO NOT stand between the ready mix truckand the pump. If the driver’s foot would slipoff of the clutch while he was backing, youcould be crushed between the two machines.

Look at the concrete before putting it into your hopper.If the mixing fins of the truck are badly worn, the mixwill not be homogenous (that is, the rock, sand, cementand water will not be properly mixed). Do not allow achute full of grey colored rocks to be put into yourhopper...it is almost a certainty that you will plug theline before you get concrete out of the pipe. If this isthe case, have the driver dump the first chute off to theside, and then display the next chuteful. In most cases,the mix will look a lot better after the first chuteful isdumped. If not, dump the next chute to the side also.You will learn by experience what mixes can and can’tbe pumped and how the two look. Once the mix looksgood, turn on the pump in the ‘forward’ mode, andhave the driver fill the hopper.

Pump slowly and watch the concrete pump circuitpressure gauge until the slurry starts to escape from thepipe and/or hose. If the pressure approaches the reliefvalve setting of 300 bar, immediately switch the pumpto ‘reverse’ mode, and notify the ready mix driver tostop dumping. Give the unit one or 2 strokes in reverse,then go back to ‘forward’. If the concrete continues toslide without high pressure, then you’re OK. Ifpressure again rises towards the relief setting, repeatthe reverse cycle. In many cases you can prevent ablockage by “rocking” it back and forth. In fewercases, the plug will not cooperate and you will need tofind the source of the blockage and remove it manually.

NOTE!You must not open a blocked pipelinewithout first sucking the concrete back intothe hopper! the act of putting the pump intoreverse for several strokes will release thepressure on the blockage. understand thesafety rules for opening a blocked pipe asshown in the Safety Manual section of thisOperation Manual.

With an accumulator, speed control is available as soonas the engine is started. You do not have to wait for asteady hydraulic pressure in the concrete pump circuitbefore you can use the stroke limiter to change thestrokes per minute of the pump.

Once concrete has emerged from the point ofdischarge, stop pumping. If you are pumping into apipeline, wait for the start signal before you begin topour.

To control the speed of the unitThere are two ways to control the speed on this unit: bythe stroke limiter by the engine throttle.

The stroke limiter is a hydraulic device that can beadjusted at the operator’s panel. Its function is to raiseand lower the output of the hydraulic pumps thatoperate only the concrete pump. This has the advantageof allowing the engine to remain at higher RPM, wherehorsepower is at the maximum. With an accumulator,there is pressure in the system as soon as the engine isstarted, and therefore you can use the stroke limiterimmediately to control the speed. Basically, it willwork whenever there is 50 bar or more showing on theconcrete pump circuit pressure gauge. It has anadjustment range of 100%. That is, it can go from zerostrokes per minute to maximum strokes per minute.Beware...because it can go to zero strokes per minute,it is possible to stop pumping altogether by adjusting

Operation


this valve. On single circuit machines, the strokelimiter only adjusts the output of the hydraulic pumpswhile the differential cylinders are moving. That meansthat when the differential cylinders are stopped at theend of the stroke and the rock valve is moving, the

pumps return to maximum output until the rock valvecylinder has completed its travel. This interruption ofthe stroke limiter signal is known as ‘fast switch’. It isrecommended that all output control be done by thestroke limiter and not the engine throttle (Figure 49).

To control the speed of the unit by the engine throttle,simply speed up or slow down the engine. This has theeffect of turning the hydraulic pumps slower, whichresults in less hydraulic fluid output. This method ofspeed control is primarily used when you want to limitALL of the hydraulic circuits...agitator, concrete pump,etc. It has the disadvantage of lowering the horsepoweroutput of the engine. It is possible to kill the enginewith the hydraulics of the unit, if you lower the RPMtoo much.

Try to match your pumping speed to the needs of theplacement crew and with the supply of concrete. Itdoesn’t do any good to bury the crew with concrete,then wait for half an hour for the next truckload ofconcrete to arrive.

Pump the jobIf you are not able to see the point of discharge fromwhere you must operate the unit, be sure your spotter isin position before starting the pump.

Once you get the start signal, put the pump in forward,and alert the ready mix driver to start dumping.

Concrete must always cover the openings of thematerial cylinders or you will suck air into the materialcylinders. If this happens, there will be a suddenexpulsion of concrete on the next stroke as the nowcompressed air escapes. This could be dangerous, so besure that the ready mix driver understands the situation.If you have taken air in to the material cylinders, youcan cushion the expulsion by stopping the concretepump and filling the hopper with concrete before thenext stroke. The mass of the concrete will prevent thecompressed air from pushing anything out of thehopper. Once the hopper is full, it is safe to resumepumping. Even with the hopper full of concrete, somecompressed air will be introduced into the deliverypipeline. When it reaches the discharge point, the airwill cause a sudden expulsion of concrete. If the hoseperson is walking a wall or column, or is otherwise in aprecarious position when this expulsion happens, itcould cause an accident. Best is to avoid ever suckingair into the material cylinders, but if it does happen,YOU MUST WARN THE HOSE PERSON.

Figure 49Showing adjustment of the manual stroke limiter

Operation


Point out the emergency stop switches to the driver ifyou will be standing somewhere other than at theoperator’s panel. That way, the driver could warn youor stop the machine if he sees a dangerous situationdevelop.

Always keep an eye on the point of discharge, or yourspotter. If the hose man is giving you signals, he willhave his hands full and will not be able to jump up and

down or wave his hands to get your attention. On atypical job site, it is doubtful that you could hear himyelling.

As the day progresses and the crew removes pipesections from the end of the slickline, wash the pipes,clamps and gaskets with water (Figure 50). If you don’twash them until the pour is finished, you will not beable to get the hardened concrete out of them. This jobcan be done between loads of concrete, or by an oileror laborer at almost any time.

Time ConstraintsRemember, if anything goes wrong on the unit while itis pumping, you only have 15 to 30 minutes to solve itbefore the concrete sets (less with old concrete on a hotday, more with fresh concrete on a cool, cloudy day). Ifyou know that it will take longer than that to fix, cleanout before you begin repairs. If concrete is beginning toset, you will have to clean out in a very quick andefficient manner. There are special instructions forquick clean-out, which you will find in this section(Section 5), starting on page 124. If you keep yourhead and keep moving, you can usually avoid thedreaded “pipe party”, even with unfavorable pumpingcircumstances. Old concrete and hot days make up theworst case scenario. Under certain hot weather and oldconcrete circumstances, the concrete may go frombeing pumpable to setting very, very quickly. This is

called “flashing”, and if it happens to you, you maylose some pipe. See also the section on delaysdescribed in Item on page 114.

If you are pumping in very cold conditions (below+10° F.) the concrete could freeze. In this case, themachine will act like the concrete has set, but all is notlost. As long as the concrete is frozen, it cannotcontinue to set. If this happens to you, you are donepumping for the day. You will not be able to clean outat the job, unless they have a heated area where youcould move the pump for clean-out. If not, inform sitemanagement and your company, load the pipe andhose, gather up your things and find a heated area forclean-out. Further information can be found in thechapter entitled, “Cold weather pumping” beginningon page 124.

Figure 50Wash slickline as it is removed

from the pour

Operation


To disable the entire unit in an emergencyIf an emergency arises that requires that the hydraulicsystem be disabled completely, for example if a hose orfitting broke, you must stop the engine. If you are facedwith this, do not hesitate or investigate first. Shut offthe engine, then investigate. It is recommended that along length hose of each of the possible 4 diameters bekept with the unit for such emergencies. See page 4 ofthe Appendix (Section 7), for a list of the 4 hosediameters, and the recommended length of each foremergency use.

If you lose electricity on the unit for any reason, thedump valve will open. This will route oil from thehydraulic pump directly back to the tank. This is alsowhat happens when any emergency stop button ispushed. To continue pumping, you will have to find outwhat happened and fix it. If you cannot find out whathas happened within 10 minutes or so, you will have totake action to prevent the concrete from setting up orfreezing. For information on where to look and what todo if you lose electricity on the unit, contact theSchwing Service Department at (651) 429-0999.

DelaysThere will be delays. Sometimes you will have to waitfor concrete, sometimes the workers will be scramblingto finish the next form to be pumped, sometimes a formwill fail through no fault of your own, or half a dozenother reasons. You can make good use of this idle timeby washing pipe, clamps and gaskets that have beenremoved from the delivery system, washing splashedconcrete from your hopper area, eating lunch orwhatever. The important thing to remember is thatconcrete begins to set as soon as it becomesmotionless. Every 5 minutes or so, give the pump astroke, which will make the concrete in the elbows andreducers change their shape, thus breaking the set. Ifyou have to wait more than one or two 5 minuteperiods, you will have to continue differently fordifferent situations. In either case, remember this:Concrete setting in the pipe acts like a blockage.Blockages can be dangerous, because the pumpwill create maximum pressure on the concrete.If you are waiting for concrete to arrive, Do not letthe hopper become less than half full. If theconcrete is getting stiff, add water to the hopper whileyou are waiting. A word of warning regarding thisprocedure...The concrete will eventually set upanyway. If you have to wait so long that the concrete is

setting, it would be better to clean out and start overwhen the fresh concrete has arrived. This has the addedadvantage of making Murphy’s Law work for you...assoon as you begin to clean out, the concrete will arrive.

If you are waiting for a form to be finished or repaired,or anytime that the delay has nothing to do withwaiting for concrete, you can give the pump one or twostrokes in 5 minute intervals for a longer time, becausethe ready mix truck will be able to refill your hopper.Be careful about where the concrete is going when youare giving the machine these one or two stroke cycles.If the form is broken, you will be complicating mattersby putting more concrete in there. Eventually, you haveto make the call...once concrete begins to set while it isbeing pumped, you have only minutes to get themachine cleaned out. For this procedure, see thechapter on clean-out. Another thing to consider is thecondition of the concrete in the ready mix trucks. Ifyou have 3 or 4 trucks lined up behind the pump andthey have been waiting with you, their concrete is alsosetting. Let’s say you have been waiting for 45 minuteswhile a form is being repaired. The ready mix plant is25 minutes away from the job, and the driver waswaiting to get to your pump for 35 minutes before theform broke. His concrete is now an hour and 45minutes old. If it is a hot day, you are risking a “pipeparty” by pumping his concrete. You are the one thathas to make the call. Hey, nobody said the job would beeasy, did they?

Keep the waterbox fullDon’t forget to check the water in the waterboxregularly (and don’t forget to stop the pump before youopen the waterbox covers). The water is very importantfor cooling the differential cylinders, and lubrication ofthe rubber rams.

Use of the vibratorIf you are pouring very stiff concrete and it isn’tflowing well through the hopper grate, turn on yourvibrator. If you didn’t buy a vibrator with the unit, theyare available for field retrofit. Under no circumstancesshould you remove the hopper grate while the machineis operating, nor should the machine be operated whenthe grate is not in place. You wouldn’t believe some ofthe stuff that comes out of ready mix trucks. Mixer fins,clumps of unmixed cement, cats, dogs, rebar, golfclubs (you have to assume someone had a very badround), tools of all sorts, etc. Your grate will catch itbefore it goes into the hopper (providing it is in place).

Operation


If any of the listed items made it into your hopper, theywould probably cause a blockage, which is alwaysdangerous. Worse would be if you fell into the hopper.In any case, it is dangerous to operate without thegrate over the hopper.

BlockagesIf you have a blockage in your pipeline that you cannotremove by the backward / forward rocking motiondescribed on page 111, you will have to disassemblethe pipeline to find it. Before you disassemble thepipeline, you MUST relieve the pressure by pumpingin reverse for several strokes. You must not forgetthis step!

• When you go to the pipeline to find theblockage, take your hammer with you. WearALL of your personal protective devices forthis procedure. 99.9% of the time, you will findthe blockage in a reducer, hose or elbow. Theact of reversing the pump will make thepipeline sound differently, when tapped with ahammer, than if it were pressurized. ‘Tapped’is a key word here. You can damage the pipe bystriking it hard. You should be able to hear thedifference. An empty pipe has a definitereverberating “tong” sound. A relieved pipewill have a meaty “thak” sound, and apressurized pipe will have a thin “tik” soundbecause the forces on the steel will not allow itto vibrate. Once you have located theblockage, CAREFULLY remove the clamp(s)from the blocked piece(s). If you are notwearing a full face shield, turn away from theclamp as you pull the handle. Providing youhave relieved pressure by stroking in reverse,you should be OK, but sometimes a blockagewill store pressure because there is anotherblockage up or down stream. It’s better to besafe than sorry. Once the clamps are removed,the danger is past. Displace the blocked pieceenough that you can push a piece of rebar orother long poking device into it. If theblockage is in a hose, it will help to hit theoutside of the hose with the hammer. Again, donot damage the hose by hitting it so hard thatthe steel braids inside get permanentlydisfigured.

• Once the blockage is removed, clean up theclamp, gasket, and pipe end with a rag or, in apinch, wipe the concrete off with your hands.

Reassemble the pieces, and pin the clamp(s) ifthey will hang overhead. Return to the pumpand start pumping in forward again, slowly atfirst, until you are sure that there are no moreblockages. If another blockage is encountered,remember to relieve the pressure again bypumping in reverse for several strokes, beforefinding the remaining blockages.

• Do not use compressed air to remove ablockage. Your concrete pump has at least 6times more pressure available than an aircompressor. If the pump won’t push the plug,air certainly won’t. In addition, air that iscompressed builds a reservoir of pressure thatwill continue to be dangerous even when thecompressor is shut off.

Clean-outIt is an unfortunate truth, in many cases, that you willhave to wait for the “balance load” of concrete. This isusually 1 or 2 yards that weren’t ordered by thecontractor until the last minute. It usually happens latein the day, so typically 4 of the 5 ready mix drivers thatyou were seeing all day have gone home, and the sameman that brought the next to the last load will have togo and get the balance load. This gives you time to getready for clean-out and to stow pipeline, clamps, etc.,but it has the disadvantage that the concrete in yourmachine will be old by the time he returns. This is themost dangerous time for setting in the machine. Beaware of it, and take any steps necessary to keep theconcrete alive. Clean out if you have to, but if thebalance load is very small, refilling the hopper,material cylinders and pipeline may use up the entirebalance load without ever delivering concrete to theform. In that case, they would have to order anotherbalance load, and no one is going to be happy about it.When the balance load arrives, it is usually freshconcrete. That means that if you pump at least 1/2 yard,your machine will be filled with fresh concrete forclean-out, which is to your advantage. The worst thingthat can happen is: On a hot day, the balance load isonly 1 wheel barrow full. You will not be able to getfresh concrete all the way through the pipe when youpump the balance load, so the concrete that is in theend of the pipe for cleaning is as old as the next to thelast load. BE CAREFUL! With old concrete it isimperative that the pipe is cleaned immediately uponfinishing the pour.

Operation


Check Your Water Supply! You Will Need Water ForClean-out.

If you will be cleaning the pipeline by pressing asponge ball through the line with air or water, youshould wet the ball first. A lot of operators simply filltheir 5 gallon bucket with water and throw the ball in tosoak when there’s about a half hour of pumping left.Other operators start soaking the ball first thing in themorning, but the ball won’t last as long if it is always inwater.

Clean the hopperTap on the “T” handle that opens the clean-out door onthe bottom of the hopper with your hammer (Figure51). When the door opens, the concrete at the bottom ofthe hopper should fall out. If it doesn’t, put the pump in“REVERSE” mode for a couple of strokes. If thatdoesn’t work, turn the pump to the “NEUTRAL”, or“OFF” position. WARNING! Do not do the followingprocedure while the pump is engaged in either‘forward’ or ‘reverse’. The pump must be “OFF”.Aim your hammer upwards and pound any materialthat is lodged in the clean-out door. More than likely, acouple of taps will free the material. If not, you willhave to keep tapping until it is free. This procedure canbe minimized or eliminated by putting sand in thebottom of the rock valve housing before you beginpumping, as documented on page 106.

WARNING

Hose whip hazard! Never use compressed air to clean out rubber hose. The result could be a violent whip of the hose as the air is released. If water must be conserved, dump the hoses manually and rinse them with the water nozzle.

hose

whi

pwar

n.ep

s

Figure 51Open the clean-out door

Operation


Be sure of your footing and keep the hopper grate inplace for the following procedure. Spray water into thehopper from above (Figure 52). Keep the agitatorturning until you have sprayed the blades clean. Washthe material from the hopper out of the clean-out dooron the bottom.

SWG98n186.eps

Figure 52Clean the agitator and hopper through the grate

with water

Operation


Stop the agitator from turning by centering the handvalve. Do not proceed to the next step until this is done.You will be able to visually confirm that the agitatorhas stopped by looking in the hopper (Figure 53).

Figure 53Stop the agitator by putting it in the center (neutral)

position. You can access the agitator control only from the right side (operator’s control panel side).

Operation


Poke any material that has set in the corners of yourhopper with a piece of rebar or other stiff, long bar(Figure 54). Do not remove the hopper grate for this,or any other clean-out procedure. This procedurecan, and must be done with the hopper grate in place.

Don’t spend too much time on this procedure, or theconcrete will have time to set up in the rock valve andmaterial cylinders.

If concrete in the hopper has completely set, you willneed to use a chipping hammer or other power tool toclean it. The grate is removable for this purpose, butthe hydraulic system must first be disabled bystopping the engine and removing the key. For safetyreasons, it is recommended that you return to your shopbefore removing any concrete that has completely set.Once the concrete has set, there is no advantage tochipping it away at the job site.

Figure 54Remove built up concrete from the hopper with a piece of

rebar or similar device

Operation


Clean the rock valve and material cylinders

Once the hopper is clean, you should clean out the rockvalve and material cylinders. Before you begin thisstep, bring the engine speed to an idle. Stroke theconcrete pump one complete stroke in “REVERSE”,until the rock valve shifts across, then stop the pump.This step assures that the material cylinder that isexposed will have the rubber ram extended to the end,

thereby eliminating the need to pull material from deepinside the cylinder. Be sure that the concrete pump isturned to the “OFF” position before proceeding. Getyour clean-out rake, and pull any material from theexposed material cylinder, the rock valve, and theoutlet pipe (Figure 55).

Figure 55Use the rake to remove material from the rock valve and material

cylinders

Figure 56Never put your hands in the concrete valve

Operation


NOTE!DO NOT PUT YOUR HANDS INTO THEVALVE HOUSING AT ANY TIME (Figure56)!

Spray water into the opening, washing the end of therubber ram, the material cylinder, the rock valve andthe outlet pipe. Continue washing until the water thatleaves the valve is clear and clean. Visually inspect thatno rocks, sand or clumps of concrete remain. If there isstill material, continue spraying (Figure 57).

Be sure that your rake, and everything else is out of thevalve area, then cycle the machine in reverse for onemore stroke. This will expose the opposite materialcylinder, and completely extend its rubber ram. Pullany loose material out with the clean-out rake, thenspray out the material cylinder as in the previous step.

By putting the pump in the “REVERSE” mode, you aresucking from the pipeline (which is not connectedduring the clean-out procedure) and pumping into thehopper. Because of this, you may find that you nowhave some material in the bottom of the hopper again.You should now wash this material out.

Spray off the clamps, gaskets and wedges.

Close the hopper clean-out door, and reattach thebungy cord, if used.

Be careful with acid

Many aggressive cleaning compounds can do damageto chrome and rubber seals. Always follow directionsvery carefully when using such cleansers.

WARNING

Amputation hazard. Stop pump before cleaning the Rock Valve and hopper.

0000

15.e

ps

Figure 57Spray out the rock valve and

material cylinder

CAUTION

Chrome and rubber seal damage. Be very careful when using aggressive cleaners around chrome and rubber seals.

Cau

tion.

eps

Operation


Clean the waterbox

NOTE!The waterbox is an integral part of thepump kit and provides lubrication andcooling to the pumping cylinders andhydraulic system.

The waterbox needs to be cleaned andflushed daily. Dirty water will not have thesame flushing or cooling effect as cleanwater. Hydraulic oil expands up to 5% whenheated. It is for this reason the waterbox hasto be drained after every job. As the oilcools, it shrinks up in the differentialcylinders, and can actually pull water inover the rod packings.

To clean the waterbox, start by lowering the engineRPM to an idle. Leave the waterbox cover in place, fornow. Open the drain and allow the existing water toflow out the bottom. When water stops flowing, givethe unit a stroke or two in either forward or reverse.This will force the water in the extended cylinder backinto the waterbox, and therefore out of the drain. The

waterbox is empty when no more water flows out of thedrain, even after the unit is cycled. STOP THE PUMPand secure it against unintentional starting by pushingthe emergency stop button. Be sure of your footing.Remove the waterbox covers, and spray the waterboxand cylinders until all cement fines and grout are loose(Figure 58).

If you will not be filling the waterbox again until justbefore the next pour (a highly recommended practice),then you should do the following procedure:

• Replace the waterbox cover.• Put the pump into “FORWARD” or

“REVERSE” for 1 or 2 strokes, to force theclean water out of the drain.

• Close the drain.

If you need to refill the waterbox immediately, simplyclose the drain, and finish filling the waterbox. Don’tforget to replace the waterbox cover before restartingthe unit.

IMPORTANT!If the machine will be transported or stored in below freezing

temperatures, you must drain all the water out of the waterbox. See the section on cold weather operation for further details.

Figure 58Stop the pump, be sure of

your footing, then spray out the waterbox.

Operation


Preparation for travelStore your clean-out rake, sponge ball, grease gun,hammer, shovel, and all other accessories securely fortravel.

If the job was set up that you were keeping track of theconcrete delivery tickets, you should turn them over tothe concrete supervisor when you have him sign yourjob ticket.

Before you get into the cab to drive, take a walk aroundthe trailer. Look for items that you may be forgetting,look under the unit for personnel and obstructions, andcheck for air pressure, tire pressure and wear, etc.Many driving accidents happen on the way back to theshop after a job, or on the way to a second job. Thinkabout your route, bearing in mind the time of day, roadconstruction, etc. As hard as it may be, you want tobegin driving with a fresh attitude and clear head.

Special Pumping Situations

Rod side to piston side pumping (BPA 2000)The hydraulic system for the 900 and 1200 seriesconcrete pump can be configured for ROD SIDE orPISTON SIDE pumping, as shown in Figure 59.

Rod side pumping allows maximum yards per houroutput, while piston side pumping allows maximumpressure to be exerted on the concrete. (See specificinstructions for pumping on piston side in theOperation section of this manual). Piston sideoperation dramatically raises the maximum pressure onthe concrete. For this reason it is crucial that yourentire material delivery system be rated to handle theavailable pressure and kept in “like new” condition.Remember that pipe wears with each yard pumped.Inspect the wall thickness regularly. The maximummaterial pressure available on piston side depends onwhich differential and material cylinders youpurchased with your unit and is stamped into the mainID tag.

When configured on ROD SIDE, the hydraulic oil isrouted from the S2 valve to the differential cylinders atthe port on the rod end (the end from which the rodprotrudes). The rocking oil loop hose is connectedfrom one cylinder to the other on the piston end.

When configured on the PISTON SIDE, the hydraulicoil is routed from the S2 valve to the differentialcylinders at the port that is on the piston end (the endaway from where the rod protrudes). The rocking oilloop is connected from one cylinder to the other on therod end. Note that the rods are moving the samedirection in both examples shown, whether they areconfigured for rod side or piston side pumping. This isaccomplished by crossing the lines from the S2 valveas shown, and is necessary for the purpose ofmaintaining the proper sequence of action so theconcrete valve is timed with the movement of thedifferential cylinders.

pistonsidehoses.eps

Figure 59Hose configuration for rod side pumping

with a BPA 2000

Operation


Quick Clean-outIf concrete is setting up in the machine, you will haveto clean out in a hurry. It is important that youremember the safety rules when cleaning a settingmachine. Accidents happen when you panic. Stay calmand work as fast as you can without skipping any safetyrules.

You should prioritize the order of clean-out withregards to the extent of the setting action. Basically,you should keep in mind the amount of time andmoney involved to replace any components that areruined by failure to clean before the concretecompletely sets. To help you make this decision, wehave included the following list which is arranged inorder from most expensive and difficult to replace, toeasiest and cheapest to replace. We are not suggestingthat you clean out in the same order, but it may help indetermining where you want to start.

• Rock valve cast housing• Rock valve• Material cylinders• Hopper• Pipeline

In practice, an experienced operator will dump thehopper and material cylinders, and rake out the bulk ofthe material from the valve in just a couple of minutes,moving immediately to the pipeline. The rest of thematerial in the hopper and valve can be chipped out if itwon’t wash clean. Be sure to disable the hydraulicsystem on the unit by stopping the engine, putting thekey in your pocket, and putting a “DO NOTOPERATE” tag on the ignition switch before enteringthe valve/hopper area for chipping.

When cleaning a setting machine, don’t worry aboutgetting each part perfectly clean before moving on tothe next part. Once you have used water to remove thebulk of the concrete from a component, it will bethinned enough to not completely set until you can getback to it.

Cold weather pumpingIt is possible (and routine in some parts of the world) topump concrete with outside temperatures as low as-10° Fahrenheit, and even colder under certaincircumstances. This can present a variety of problemscompared with pumping in moderate temperatures,such as:

• Water in waterbox freezes while you aredriving to the job.

• Hydraulics are slow and sluggish.• If it’s very cold, concrete can freeze in the

pipeline while you are pumping.• Concrete freezes in the hopper.• The concrete will be loaded with calcium

chloride or an equivalent to allow the concreteto set before it freezes. This will acceleratesetting, in much the same manner as a hot dayaccelerates setting.

• Anything you wash with water becomes coatedwith ice, which will not melt and evaporateuntil the temperature raises above freezing.

• Machine parts that you touch become veryslippery if they contact any water.

Some of these potential problems can be solved ortolerated, others cannot. A majority of the time theconcrete will be mixed using very hot water, to keepthe concrete from freezing during the delivery andwaiting period. Some tips for cold weather pumping:

Store the machine indoors in locations that have coldwinters, like the northern U.S. and Canada. If you don’thave a heated shop for the winter, consider renting one.

Do not put water in the water tank or the waterboxbefore driving to the job. If possible, contact the readymix company and arrange for the first driver to beloaded with hot water to fill your waterbox and to mixyour slurry. Arrange for the last driver to be full withhot water and prepared to let you clean out using thiswater.

Operation


If you are expecting cold weather for extended periodsof time, such as winter in the northern United Statesand Canada, you should change your oil to a thinnerviscosity type, such as an ISO VG 32, which will giveyou a lower pour point. Be aware, however, that this oilcannot protect the components to as high a temperatureas the standard oil shipped with your unit (DTE 15).

Preheating the hydraulic oilAnother option is to preheat the oil before beginningthe pour. This will require that you order a hydraulicshut-off valve, and install it as shown in Figure 60. Thepart number of this valve is 10004680. You will have toarrive at the job early enough to do the procedure.Allow about 10 or 15 extra minutes. To preheat the oil:

• Start the motor, but do NOT rev the engine tofull RPM until the hydraulic oil is warm (atleast 20° Centigrade). If you do, the hydraulicpumps will not be able to suck the thick oil asfast as they are turning, resulting in pumpcavitation and damage to the pumps. Leave theengine at an idle.

• Close the quarter turn valve.• Let the machine idle until the oil is at 20°

Centigrade, then rev the engine to half throttle.• Continue heating the oil to 50° or 60°

Centigrade.• Open the quarter turn valve.

There’s nothing you can do about a separately laidpipeline. In most cases, pours that require a separatepipeline will cancel if it is very cold. If they don’tcancel, there is a good chance that you will not be ableto get concrete through the line because the slurry willfreeze against the walls of the pipe, then the concretewill have to be pushed through the pipe dry. This could

result in a blockage. To clear the line, all normalblockage steps should be taken and additionally, youhave to work fast enough that the concrete doesn’tfreeze before you get it moving.

If the concrete freezes in the pipeline, you are donepumping until you have warmed up the machine. Thegood news is: the concrete will stop setting when it hasfrozen. Once you bring the machine into a warm place,you will be able to clean it.

If the concrete freezes in the hopper, you are donepumping. Find a warm place to bring the machine andclean it as it melts.

If the concrete is loaded with calcium chloride, youwill have to keep the concrete alive using the sametechniques used for pumping on hot days. The calciumchloride accelerates setting, but if it does freeze, thesetting stops. When you do begin to thaw the machine,the concrete will begin to set again, even more quicklythan on the job, because you are now in a warm area.Do not waste time when cleaning a machine underthese circumstances.

Be very careful of ice when pumping in coldconditions. Ice can form on all objects and surfaces.

000174.eps

Motor

Agitator quarter turnshutoff valve (open position)

Figure 60Quarter turn valve installed in

the agitator circuit.

Operation


Maintenance

Line pumpsStartup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve models:Frame files:Maintenance.fm Operation Manual - 127

MAINTENANCE

Filtration ..........................................................................................................128 Hydraulic Oils..................................................................................................130 Pressure, Hoses and Fittings..........................................................................130 General Maintenance Tips..............................................................................132 Preventative Maintenance ..............................................................................133 Scheduled maintenance checklist ..................................................................143 Unscheduled maintenance .............................................................................144

swg99a001.eps

Maintenance


MaintenanceMaintenance is what you do to the machine to keep itin good working condition. There are two kinds ofmaintenance, preventative and repairs. Preventativemaintenance is important to avoid unnecessary repairs,but eventually even well maintained machine parts willwear out and require repair or replacement.

Some maintenance needs to be done daily, someweekly, some monthly, some quarterly, somesemiannually and some annually. It is a good idea tomake a checklist that will tell you what maintenance isdue, and when it is due. A checklist is included in theAppendix section of this manual. Keep accuraterecords of maintenance performed, and when the workwas completed. In this way, you will know that allnecessary work has been completed on time. Completemaintenance records could also make the machineworth more money when it comes time to sell or tradeit.

There are certain things you should know about themaintenance of your machine that will not come up ona timetable of things to do.

We begin the section with some general informationregarding some of these items.

Filtration

General InformationFiltration is the single most important method ofkeeping your unit’s hydraulic system operational.Particles that could damage the components areintroduced into the oil by the differential cylinders andthe valves, through the reservoir breather tube, and byinternal wear in the components themselves.Additionally, when you change hydraulic oil the newoil is not clean enough to be used in a concrete pumpwithout being pre-filtered. In fact, new hydraulic oil isonly filtered at the refinery to 40μ (40 microns). The oilin a Schwing needs to be filtered to a MINIMUM of25μ, and preferably finer than that. Filters are rated by:

• the size of particles they trap, and whether thatsize is nominal, or absolute

• the dirt holding capacity, in grams• the clean element pressure drop for a given

flow rate (in PSI and gallons per minute or barand liters per minute), and

• the ratio of particles of a given sizeencountered versus particles passed (referredto as the beta ratio). An example of a beta ratiowould be β25 = 200 (pronounced beta twentyfive equals two hundred). This means that forevery 200 particles of 25 microns or larger thathit the filter media, one makes it through. Afiner filter would be, for example, β12 = 200.A courser filter example would be β25 = 75.For concrete pumps, medium to fine filtrationis required.

NOTE!It is recommended that after an initial 100hour break in period, both the hydraulic oiland filter and motor oil and filter bereplaced. Check with Schwing service forthe correct lubricants and filter to use inyour climate.

Specific InformationHere are some facts regarding filtration as they relate toyour pump:

As delivered from the factory, each Schwing isequipped with a return filter that is rated at 12 micron(shown as 12μ) absolute.The beta ratio is β12 = 200. In our case, the beta ratiomeans that for every 200 particles of dirt that hit thefilter media that are 12 micron or larger in size, 1 willmake it through. Although we are not happy about theone particle that is allowed through, we do not use finerfiltration because A) the components don’t require it,and B) a finer filter would plug up with dirt too often,resulting in high maintenance costs to you. We havesettled on a compromise that should afford long servicelife and minimum maintenance costs. Don’t be fooledby the one particle that gets through, this is anextremely high quality element with very goodtrapping characteristics.The clean element pressure drop is about 6 PSI at 200liters per minute (element only) + 2 PSI for thehousing, for a total of 8 PSI ΔP when the element isclean. The pressure drop varies with the viscosity ofthe oil, which is why you can ignore the delta P pop outindicator until the oil is heated to normal operatingtemperatures.It will hold between 75 and 80 grams of dirt, whenoperating at a flow rate of 200 l/m. The flow rate isimportant, because the filter would hold more if you

Maintenance


operated at a lower flow rate. Good filtration is notcheap, but it will save you thousands of dollars bypreventing component failure.

The return filter is equipped with an integral bypasscheck valve, with a spring force of 50 pounds. Thatmeans that when the filter is clogged with dirt and oil ishaving a hard time making it through, the pressuredifference between the filter inlet and the tank raises.This pressure difference (commonly referred to as apressure differential) is called delta P, and is shown asΔP. When the ΔP reaches 50 PSI, the check valve opensand the oil returns to the tank unfiltered. If the filter didnot have the bypass check valve, it would simply breakapart when it was clogged. That would put all of thedirt that it ever trapped directly into the system, plusthe element itself would become a contaminant.

The pumps are equipped with a medium pressure filterassembly that has been manufactured especially for us(Figure 61). It is equipped with an integral bypasscheck valve, set at 50 PSI. The bypass valve protects

the filter element from damage due to running with aclogged filter or cold starts. The assembly is equippedwith an anti-back flow check valve, which prevents oilfrom draining out of the tank while you are changingelements. There is a delta P indicator to tell you whenthe element is dirty (set at 35 PSI). You should replacethe element whenever the indicator pops out and the oilis above 20 degrees Celsius. Under normalcircumstances, the element will need replacementabout every 6 months. The element has been designedto remove all particles large enough to cause unduewear and job site breakdowns (beta 12 = 200). You cankeep the hydraulic system running year after year byreplacing the element when replacement is due. Do notsubstitute “will fit” elements in this housing.

To change the element:a. Make sure the engine is shut off.b. Position a pan or bucket under the filter

housing to catch drips.c. Use a filter wrench to remove the old filter.

The type of filters installed on your unit are the resultof years of experience and testing. We recommend thatyou DO NOT change the housing or element to someother type. You may learn that, in the long run,sometimes cheaper is more expensive.

oilfilter.eps

Figure 61The main return filter

Maintenance


Hydraulic Oils

General InformationHydraulic oils are rated for viscosity, heat dissipation,foaming characteristics, pour point, anti-wearadditives, anti-corrosive additives, lubricating qualities,compressibility, temperature range, temperaturestability, and other functions. Although many differentbrands of oil will meet these specifications, they mayuse different chemical additives packages to achievethe end result. For this reason, you should not mixdifferent brands of oil. The additive package from onebrand may be incompatible with the additive packagefrom the other, rendering both packages useless.

Recently a few manufacturers have introducedbiodegradable hydraulic oils into the market. These oilsare based on vegetable extracts instead of mineralextracts. They are considered safer for the environmentin the event of a spill, although the additive packagesare not inert. One brand, Mobil EAL 224-H has beenaccepted for use in Schwing pumps, and other brandsare under consideration and testing now. The mainthing that you have to remember about these oils is thatthey must NOT be mixed with mineral based hydraulicoils, even in very small amounts. If you will bepumping a job in an environmentally sensitive locationand wish to use this type of hydraulic oil, pleasecontact our service department at (651) 429-0999 forinstructions on making the change from mineral oil.

Viscosity of hydraulic oil is similar in concept to thedifferent weights of motor oil. For example, in thewinter you may run 5W-30 in your car, while in thesummer you run 10W-40. The same is true forhydraulic systems. If you live in a climate where theweather is changing from extremely hot conditions toextremely cold conditions, you should considerchanging the weight of the hydraulic oil that you use,by the season. The International StandardsOrganization (ISO) has developed a method of gradinghydraulic oils for viscosity. For summer in northernNorth America, we recommend ISO VG 46 weight oil,while in the winter we would recommend ISO VG 32or even VG 22, depending on how cold it gets in yourarea. For southern North America and Central Americawe recommend ISO VG 46 for the winter, and ISO VG68 or VG 100 for the summer, depending on how hot itgets. The lower the ISO VG number, the thinner the oilis, and the lower the pour point of the oil is. On theother hand, the thinner the oil is, the lower the

temperature will have to be before it breaks down thelubricating film that protects your components. See thechart in the Appendix section of this manual for help inselecting the proper oil for your requirements.

The quality of the oil needed for use in a Schwingmachine is rated in the DIN system. The ratings have todo with the chemical additive package that isintroduced into the oil. Both the DIN rating HLP andHV qualities are approved for use in our machines.

Specific InformationAll machines leave the Schwing factory filled withMobil DTE 25 hydraulic oil unless otherwise requestedby the customer. DTE 25 has an ISO viscosity rating ofVG 46. If you want your new machine filled with adifferent brand or different viscosity oil, you shouldspecify when ordering.

Many other brands of oil have been approved for use inSchwing machines, including:

• Texaco Rando HD and Rando HDZ• Shell Tellus oil• BP Energol• Aral Vitam• Esso Nuto• Esso Univis• Total Azolla• Wintershall Wiolan

(The order of the list doesn’t signify anything. Any oilwhich meets the quality and viscosity standardsdescribed above can be used).

When to change your hydraulic oil

You should change your hydraulic oil at least once peryear. If you use good filters and change them whenthey are dirty then the oil will be clean, even after ayear, but the chemical additive packages that give theoil its properties will break down with time, and noamount of filtration will bring them back.

Pressure, Hoses and Fittings

General InformationMost concrete pump hydraulic systems run with fairlyhigh pressures, in the 2000 to 5000 PSI range. Themaximum pressure is determined by adjustment of the

Maintenance


main relief valve, and the machines are designed tohandle this pressure safely. Concrete pressure is just aratio of the hydraulic pressure.

If you lower the pressure at which the system runs, youcan harm the system. For example, you ask themachine to develop 3000 PSI hydraulic pressure topush the concrete where you want it to go. You want toreplace a hydraulic hose with a less expensive, lowerpressure hose, so you lower the relief valve settingfrom 4350 PSI to 2500 PSI. What is the result? Theconcrete still requires 3000 PSI to get where you wantit, but your relief valve opens at 2500. Now the oil thatshould be pushing the concrete is traveling back to tankinstead. All of the horsepower that it took to send theoil out of the pumps at 2500 PSI is turned to heat,which will boil the oil. The oil (in this example) losesits lubricating qualities at 80° Centigrade, socomponents begin to wear, sending debris downstream, which adds to the wear. The system would bedestroyed in minutes if it continued to operate underthese conditions.

If you raise the pressure at which the system runs, youcan harm the system. Using a new example, theconcrete requires that the machine develop 4900 PSIhydraulic pressure to push it where you need it. Yourmachine is factory set to run at a maximum of 4350PSI, so you raise the setting of the main relief to do the

job. The hydraulic pump can’t withstand 4900 PSI formore than a few minutes and it breaks. You now have toreplace a pump before you can make another pour.

If you leave the machine at the factory specification,you DO NOT harm the system. It gives you years ofdependable service. This means you should only usefittings and hoses that have a sufficient WORKINGPRESSURE to handle the system requirements and ifyou take a job that needs more pressure than yourmachine is capable of, you should buy or rent a higherpressure machine.

Specific InformationSchwing uses high pressure fittings and hoses on allcircuits, even if the relief valve for that circuit is set tolow or medium pressure. The fittings and hoses arerated at a minimum of 5000 PSI working pressure, andin the case of some fittings, up to 15,000 PSI. Weadvise against changing any circuit to lower ratedhoses or fittings.

We use metric fittings and hoses, with metric threadson the couplings. There are four diameter sizes of tubesand fittings used on this unit, and four diameter sizes ofhoses. The chart below tells you what the sizes are, andwhat they will attach to.

All block threads are metric or BSPP.

Instructions for setting the relief functions are shown inthe preventative Maintenance section of this manual.

Hose SizeHose ID

8

(mm)

13 13

16 16

20 20

32 32

Connects with Fitting and Tube Size

12

16

20

25

38

hose/fittings chart.eps

8

25 25 30

12

16

20

25

38

Tube andFitting Size

Connects withHose Size

Tube andFitting OD

12

16

20

25

38

Tube andFitting ID

8

13

16

20

32

(mm)(mm)

30 30

8

13

16

20

32

25 25

Figure 62Showing hose, fitting and tube

sizes and equal connection sizes.

Maintenance


General Maintenance Tips

Torque SpecificationsWhen performing maintenance that requires removaland replacement of bolts, it is very important to adhereto the torque specifications that apply to that bolt(Figure 63).

The graphs in Figure 63 demonstrate what happens to abolt if it is not properly torqued. The dashed linerepresents the prestress on the bolt. As the device thatuses the bolt goes through its normal functions, the boltin example “A” gets stretched and relaxed with everyduty cycle, because the bolt is prestressed under themaximum force of the cycle. In example “B”, theprestress of the bolt has been raised to more than themaximum force of the duty cycle, so the bolt doesn’tever feel the cycle. In this example, bolt “B” would lastMUCH longer than bolt “A”. The torque specificationsfor bolts used on Schwing equipment are found in theAppendix section of this manual.

Adjusting relief valves.While adjusting a relief valve is not normally adangerous procedure, you should remember that it hasthe potential to cause trouble. The main thing to watchout for is this: Sometimes people that don’t know betterwill have a problem with a machine and begin troubleshooting by raising the relief valve setting. When thatdoesn’t help, they forget to lower it back down. Nowwhen you check the pressure by creating a hydraulicdead block, the pressure is set too high. In extremecases, this can cause hoses or fittings to burst, or othercomponent failure. To be safe, you should begin theadjustment procedure by turning the adjustment deviceto the lowest possible setting, then bring the deviceback up to the proper setting.

Removal of safety devices.Sometimes you will have to remove a safety guard orother safety device in order to perform maintenance.For these situations, you must take extra care to be sureof your own safety, and that of your co-workers. If youhave to put your hands, feet or any other body part intoa part of the machine that would normally be guarded,be sure that the machine is turned off and that the key isin your pocket. If there is more than one key inexistence, you should also put a “DO NOT OPERATE”sign on the controls or over the start switch. Lock outtags were provided with you pump when it wasdelivered (Figure 64).

Before restarting the machine after performingmaintenance, be sure to put away all tools, parts andsupplies, and clear the area of personnel. If yourcompany has a “lock out - tag out” policy in place,abide by it.

Concrete pumps are big enough to hide a man. Be sureto yell “clear” before starting the unit at any time, andallow time for response before proceeding.

SWG98n175.eps

Figure 63Showing the effects of proper prestressing of a bolt.

Front Back

DANGER

LOCKEDOUT

DO NOT OPERATE

This lock/tag mayonly be removed by:

Name ________________Dept. _________________Expected Completion_____

XYZ Company No. 12345

DANGER

This unit has beenLOCK OUT

Only the individual whosigned the reverse side

may remove this lock/tag.

Remarks: ________________________________________________________________________________________________________________________________________

lockout.eps

Figure 64Lockout/Tagout provided with unit

Maintenance


Preventative MaintenanceNOTE!

There is a sample maintenance chart shownin the Appendix of this manual, beginningon page 156.

Daily Maintenance• Check the levels and condition of the

lubricants and coolant in the towing truck.Follow the manufacturers recommendationsfor quantity and type.

• Bleed the moisture out of the truck air systemby opening the pet cocks located on the bottomof the air tanks. This is especially important ifthere is a chance that the moisture will freeze.

• Check the condition of the tires on both thetowing truck and the trailer. Do not drive theunit with bald, cracked or damaged tires.Check the wheel hubs on the trailer forlubricant. Fill the hubs halfway with 90 wt.gear lube, if fluid is below that point.

• Check the level and condition of the hydraulicoil (Figure 65). Top up, if necessary, with thesame brand and type of oil. If you have a filterbuggy to pump oil into the tank, use it. Replacemilky looking oil, which is a sign of watercontamination. Try to determine the source ofthe water, if possible. If the oil has turnedmilky quickly, like from one day to the next,then just replacing the oil will not solve yourproblem, and the new oil may be milky lookingthe next morning. If you need help with ideasof where to look for the source of watercontamination, call the Schwing ServiceDepartment at (651) 429-0999.

• Bleed the water out of the bottom of thehydraulic oil reservoir, by opening the draincock or faucet located at the bottom of the

reservoir (Figure 66). Place a drain pan underthe outlet hose, open the valve, and watch theliquid as it leaves the hose. When the liquidchanges from water to oil, close the valve.Because of condensation, which is aggravatedby large heating and cooling cycles, it isnormal that there will be a small amount ofwater in the tank every day, but it should settleto the bottom of the tank overnight. The waterthat is drained should be clear, and the oil thatfollows it should also be clear, not milky.

• Check the differential cylinder rod packings.Note! In order to conform to new Europeanregulations, beginning after 4th quarter of 1995the waterbox will be fitted with a bolt downgrate under the waterbox covers. This willmake manually checking the rod packings eachday, like we have instructed you to do in thepast, impractical. To check for rod packingwear, fill the waterbox with water above thelevel of the differential cylinder rods (if nograte is installed), or above the bolt downgrates (if installed). Let it sit for a few minutes.If oil begins to float to the top of the water, it isan indication that the rod packings are worn(oil is lighter than water, and will float). Don’tforget to let the water out after the check,especially if freezing temperatures areexpected. Failure to replace the rod packingswhen they need it will result in contaminatesfrom the waterbox, including water, enteringthe hydraulic oil at the packings and wearingon the rods, cylinder tubes, guide bushings,pistons and the piston rings. The material thatgets worn off of the above mentioned itemsalso becomes contamination, accelerating thewear. Left unchecked, this wear will totallydestroy a differential cylinder. Normally, youwill be due for new packings after 1 to 2 years.

Figure 65The hydraulic oil level

indicator.

2Koildrn.eps

Figure 66The drain cock used to drain water

from the reservoir.

Maintenance


• Each day you should visually inspect the boltson the rock valve and the rubber rams. Noticeif there is any play. If you see somethingsuspicious, shut off the engine, put the key inyour pocket and remove the hopper grate orwaterbox covers and inspect with a wrench. Ifyou find that they are loose, tighten with atorque wrench to the torque specificationsfound on page 153 of the Appendix section ofthis manual. Don’t forget to replace the hoppergrate and/or waterbox covers before using themachine.

• Grease the rock valve and agitator bearings.This can be done on the job as described in theOperation section of this manual beginning onpage 108, providing you have remembered tobring your grease gun and grease tubes.

• Visually inspect the unit for damage or leakseach day. Repairs should be made before theunit is operated.

• Once a day you should check yourmaintenance checklist to see if any weekly,monthly, semiannual or annual maintenance isdue.

• Check daily, the fluid level in the radiator. Add50% water and 50% ethylene glycol if needed.

• A heavy duty, dry air cleaner filters all of theair entering the engine. Excessive restriction ofthe air intake system reduces the flow of air tothe engine affecting horsepower output, fuelconsumption and engine life. An air restrictionindicator is installed in the air intake manifold.Visually inspect the restriction indicator dailyto assure the filter is not restricted. Service theair filter when the red diaphragm is exposed.Press the reset button on the restrictionindicator after servicing the air filter.

Weekly Maintenance• Check the rock valve tension nut for play once

each week (Figure 67). To check this nut,remove the 16mm keeper bolt, grasp thetension nut by hand and turn clockwise. Thereare many holes for the keeper bolt on thespacer behind the tension nut. The object is toplace the keeper bolt in the furthest hole thatyou can reach when you turn the tension nutBY HAND. If the tension nut will only turnenough to get part way to a new bolt hole, thenturn the it BACK to the previous hole. DO

NOT put a wrench on the tension nut to get itto go to a new hole. Overtightening the tensionnut will cause premature wear on the kidneyseal. The tension nut adjusts the free play ofthe rock valve on the kidney seal end. Wear onthe cutting ring end is compensated forautomatically by the pressure spring.Replace and tighten the keeper bolt. You doNOT have to tighten the keeper bolt accordingto the torque specifications that normally areused for that bolt size. Just be sure the bolt istight enough that it won’t fall out.

SWG98n245.eps

Spacer

TensionNut

KeeperBolt

CoverBolts (7)

Figure 67Rock valve tension nut assembly and

housing cover bolts.

Maintenance


• Rotate the cutting ring. Actually, this is moredependent on the type of concrete and thenumber of cubic yards pumped than on a timeschedule, but you should check it for wear atleast once per week, and rotate it as needed. Torotate:

a. First shut off the engine and put the key in yourpocket

b. Raise hopper grate and secure with “T” bolt.c. Loosen the tension nut Figure 67.d. Loosen the 8 cover bolts a couple of threads,

but do not remove the bolts.e. Loosen the 12 x 35 bolt on the end of the rock

shaft by the slewing lever.f. The rock valve will slide far enough out for

you to rotate the cutting ring 90°.g. Remove the hopper grate.h. From inside of the hopper, tap the cutting ring

forward, towards the spectacle plate. The ringshould pop loose (if not, loosen the cover boltsa little more, then gently pry the rock valverearwards a little more). Rotate the ring 90°clockwise. It doesn’t really matter which wayyou rotate, but to keep from forgetting whichway you went last time, we recommend goingclockwise each time. That way the rotationwill always bring up a new side.

i. Be sure that the ring is centered in the rockvalve. Tighten the cover bolts slightly, ifneeded, to be sure that the ring isn’t cockedone way or the other.

j. Be sure there is no debris between the backcover and the rock valve housing (if so,clean it out). Tighten the cover bolts justenough to bring the back plate up against therock housing. Then tighten each bolt equally,using a torque wrench. Alternate which boltsyou tighten, like you would when tightening awheel on a car. The torque specs for these bolts(M20 x 65, 8.8 hardness) is 300 foot/lbs.

k. Lower the hopper grate and secure it with thegrate lock.

l. Tighten the tension nut according to theinstructions in 5.2-1. Tighten the keeper bolt.

Lubricate mechanical moving parts with oil, or aWD-40 type of lubricant.

• Drain the moisture from the fuel filter at leastonce per week. On the bottom of the fuel filteris a drain cock, drain until moisture ceases tocome out. Also drain the water out of thebottom of the fuel tanks. Using the drain cockson the bottom of the fuel tanks.

Monthly maintenance• Check the mounting hardware of the subframe,

the oil tank, the pump kit, the differentialcylinders, and the material cylinders. Checkfor bolt tightness, cracks and otherabnormalities.

• Check all hydraulic pressures. Thespecifications for each circuit are shown below,and on the hydraulic schematic that applies tothat circuit. The schematics are all contained inthe Appendix section of this manual. Changesin pressures may indicate trouble in one ormore components, and will serve as earlywarning indicators IF you check them on aregular basis. PRESSURE SETTINGS MUSTBE MADE WITH THE OIL AT NORMALOPERATING TEMPERATURES (40° to 60°C). To heat the oil to operating temperature:

a. When the oil is very cold (at or below the pourpoint of your hydraulic oil),

• Bring engine RPM to an idle.

• Let the engine idle until the temp. gauge on the operator’s panel reads 20°.

b. When the oil is warm (above the pour point ofyour hydraulic oil), follow instructions a.through g. of item 5.3-4 below. Shut off theconcrete pump when the oil shows 40° C onthe temperature gauge of the operator’s panel.

Maintenance


Setting the concrete pump pressure

The Schwing concrete pump circuit on the WP Seriespumps are designed to be operated at a maximumpressure of 330 bar (4785 PSI). It is controlled by apressure compensated pump. To check the main systempressure see Figure 68:

a. Be sure that the waterbox covers are installedon the waterbox. We do not recommend usingthe remote control box for the followingprocedure.

b. Wear safety glasses when setting pressures.c. Start the engine.d. Close the quarter turn shut-off valves shown in

Figure 68.e. Put the operator’s panel switch “remote /

local” into the “local” position.f. Using the throttle control near the operator’s

panel, rev the engine up to full RPM.g. Using the concrete pump “forward / neutral /

reverse” switch, put the concrete pump into the“FORWARD” position. The unit will stroke nomore than once, then the rock cylinder willretract. Oil will have nowhere to go exceptover the main relief valve.

h. Read the pressure on the gauge, as shown. Itshould read 330 bar for the WP 1250, 300 forthe WP 1000 and the 750-18, or 286 for the

750-15 and the BPA 450 and 500. Return thepump to “neutral” whether in needs adjustmentor not.

i. Put the concrete pump into the “FORWARD”position again. The machine will not strokethis time, but will again develop maximumpressure. Read the pressure on the gauge. Ifmore adjustment is needed, return the pump to“NEUTRAL”, then repeat the steps until youachieve the desired pressure.

NOTE!If you cannot achieve the desired pressure,you have a problem. In this case, unscrewthe adjustment knob by several turns sothat your pressure isn’t too high once theproblem is found. Contact the SchwingService Department for advice on how tocontinue.

j. Return the pump to the “NEUTRAL” position.k. Open the quarter turn valve.l. Return the RPM to an idle and go on to the

other pressure settings, as required.

0002

76.e

ps

Closed Open

Soft switch Soft switch relief cartridgerelief cartridge

Safety relief cartridgeSafety relief cartridge

Soft switchshutoff

Soft switchrelief valve

Concrete pump shutoff(Shown in open position)

ng20.eps

Close

Figure 68The main relief valve, concrete pump circuit.

Maintenance


Setting the agitator pressure

The agitator circuit has a maximum pressure of 125 bar(1812 PSI), limited by the relief valve located in theagitator hand valve (Figure 69). There is a gauge portfor checking or setting the pressure in this circuit. Theport is located on the agitator hand valve.

To set the circuit pressure:a. Stop the unit, and put the key in your pocket.b. Remove one of the hoses from the agitator

motor and plug both the hose and the fittingwith high pressure hydraulic plugs (this stepcan be skipped if you have installed a quarterturn valve as shown in Figure 60 on page 125.In that case, simply close the quarter turnvalve).

c. Install the 0-300 bar gauge on the hose.d. Locate the relief valve on the agitator hand

valve.e. Be sure that any personnel are clear. f. Restart the engine and bring it to full RPM.g. Activate the agitator hand valve. This will send

the oil against the high pressure plug. The oilwill have nowhere to go, so it will return to the

tank over the relief valve in the hand valve.The pressure at which it relieves can be seenon the gauge. It should read 125 bar.

h. To adjust the pressure, use a 13mm wrench toloosen the jam nut and a 4mm allen wrench toturn the relief valve. Turn it clockwise toincrease pressure, or counter clockwise todecrease pressure, until 125 bar is showing onthe gauge.

i. Return the agitator hand valve to the neutralposition.

j. Stop the engine and put the key in your pocket.k. Remove the high pressure plugs and fittings

from the agitator hose and reinstall the hose onthe agitator motor.

l. Remove the pressure gauge. Replace the gaugeport cover.

m. The unit can now be restarted, if necessary.Don’t forget to put the key back in the enginebefore you go home.

SWG98n198.eps

Reliefvalve

Allenscrew 4mm

Jamnut 13mm

Figure 69Showing the agitator hand valve and gauge port.

Maintenance


Clean the oil cooler fins

Spray out the coils of the oil cooler with a high velocitywater nozzle, or pressure washer. If you use a pressurewasher, be careful not to get so close that you damagethe electric motor or bend the cooler fins.

Quarterly MaintenanceChange the engine oil, oil filter, fuel filter and checkthe air breather element after the first 100 hours ofoperation. Schwing recommends changing the oil andfilters every 500 hours or once a year, which evercomes first. Schwing uses Mobile 10W-30 in allengines. For specific grades of motor oil and generalmaintenance of your engine, refer to your Duetzoperation manual.

Semiannual maintenance

Change hydraulic oil for temperature reasons

Change hydraulic oil, if you live in a geographicallocation where the weather changes the temperaturerange drastically. If you save the oil in clean barrelsand properly store the barrels, you can reinstall this oilwhen the weather changes back. You can use the oil fora maximum of 2 six month seasons. Contact your

hydraulic oil dealer to obtain clean barrels and theproper storage procedures. CAUTION! If you ignoreproper storage procedures, the oil will become socontaminated that reuse will become destructive to themachine. If you don’t own a filter buggy for oiltransfer, consider buying one, or at least rent one forthe occasions when you change your hydraulic oil.

Charging the Accumulator

Charge the accumulator every six months or 1000hours.

a. Before you begin, you will need a charging kit(Figure 70). Do not attempt to charge theaccumulator without one. You can order the kitfrom Schwing, using part number 30390139.

b. The nitrogen bottle should only be used with ahigh pressure regulator. If it was not suppliedwith the bottle, order one before proceedingwith this job.

c. You cannot charge the accumulator with theengine running. The key switch must be in the“OFF” position. Put a “DO NOT OPERATE” tag over the key switch, and put the key in yourpocket so that no one can start the unit.

30390139

Figure 70Showing the charging kit for the Parker Model

1A4N023103QRD accumulator and a high pressure gas regulator.

Maintenance


d. Remove the valve guard and gas valve capfrom the accumulator (Figure 71).

e. Back the T handle of the gas chuck all the wayout (counter clockwise) before attaching thecharging assembly to the accumulator gasvalve.

f. Close the bleed valve and disconnect the hosefrom the valve body. This will insure that theinitial pressure reading is accurate, and preventthe pressure from escaping out of the fillinghose.

g. Screw the swivel nut to the gas valve of theaccumulator and tighten to 10 to 15 inch/pounds.

h. Grasp the T handle on the gas chuck and turn itclockwise all the way down. This will press apin into the gas valve, opening it. Read thepressure before you even hook up the nitrogenbottle. This prevents you from trying to addgas to an already overcharged accumulator. Ifthe pressure is at or above the desired setting of1450 PSI, skip to point l. If the pressure is low,continue to the next step.

i. Make sure that the nitrogen supply is shut off.Attach the regulator assembly to the nitrogenbottle. Attach the hose to the high pressureregulator and to the gas valve on the chargevalve assembly.

j. Back off the high pressure regulatoradjustment handle by turning counterclockwise.

k. Crack open the nitrogen valve (on the nitrogenbottle), raise the pressure of the regulatoradjustment handle, and SLOWLY fill theaccumulator. Shut off the supply when thegauge indicates the desired nitrogenpre-charged pressure. NOTE! If the nitrogen

bottle doesn't have at least 1450 PSI pressure,you will not be able to charge the accumulatorto 1450 PSI.

l. If the desired pre-charge is exceeded, close thenitrogen bottle valve, then SLOWLY open thebleed valve. Close the bleed valve when thedesired pressure is reached.

NOTE!Never Let Nitrogen Out Of TheAccumulator By Pressing The Gas Valve PinWith A Foreign Object. The High PressureMay Rupture The Valve Seat!

m. Let the pre-charge sit for 10 or 15 minutes.This allows the gas temperature to stabilize.

n. Recheck the gauge pressure. Add or releasenitrogen until the pre-charge is correct. Be surethat the bleed valve is closed before addingpressure.

o. When finished pre-charging, screw the Thandle of the gas chuck all the way out, thenopen the bleed valve.

p. Hold the gas valve on the accumulator, andunscrew the swivel nut. Remove the assembly.

q. Mix some soap and water to make a bubblymixture. Spread it around the gas valve cap tocheck for leaks. If a leak is found, replace theaccumulator, or have it repaired by qualifiedpersonnel. Do not attempt the repair yourself.

r. Replace the gas valve cap (tighten to 10-15inch/pounds). Replace the valve guard. The jobis complete.

Figure 71Showing the accumulator gas

valve cap and valve guard

Maintenance


BLADDER ACCUMULATOR

Cross Section of the Accumulator

1. Steel Shell

2. Bladder

3. Bladder Stem

4. Port Assemblies

5. Fluid Ports

6. Gas Valve

Maintenance


Stages of Bladder Accumulator Operation1. Without Nitrogen Charge

2. With Nitrogen Charged to pressure P1

3. Influx of hydraulic oil for storage

4. Fluid charged to maximum working pressure P3

5. Discharge of hydraulic oil

6. Fluid discharged down to minimum working pressure p2

Maintenance


Annual maintenance

Change hydraulic oil for age reasons

Change hydraulic oil, if you haven’t already done itbecause of the weather. The same filling rules thatapply to adding hydraulic oil apply to filling the tankafter draining and cleaning. To change the oil:

a. The engine must be shut off. Put the key inyour pocket.

b. The oil should be cool. This is for safetyreasons. Do not change oil that is above 120° F(50° C).

c. Drain the old oil into barrels or another wasteoil receptacle. The oil can be pumped out ofthe inspection cover on the top of the tank, ordrained out of the bottom of the tank (Figure72 ).

d. Once the oil is drained, clean the tank throughthe inspection covers using cleaning solventand lint free rags. DO NOT USE GASOLINE!Remove all of the silt from the bottom of thetank.

e. Close the drain, if open. Refill by pumpingnew oil out of the barrels with a filter cart. If nocart is available, rent one. REMEMBER!NEW OIL IS NOT CLEAN ENOUGH TOINSTALL IN YOUR UNIT. If you ignore thisstep you may begin having trouble with pumpsand valves immediately, or within the first fewdays. See the information at the beginning ofthis chapter for specific information abouthydraulic oils that are approved for use inSchwing machines.

f. Change the main return filter before restartingthe unit.

2Koildrn.eps

Figure 72Change hydraulic oil

Maintenance


Scheduled maintenance checklistThe following is the normal recommendedmaintenance schedules (after the break in period).

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Check Engine Fluid Levels √ 133

Check Tires √ 133

Check Hydraulic Oil √ 133

Bleed Moisture From Hydraulic Tank √ 133

Check Differential Cylinder Rod Packings √ 133

Inspect Bolts On Rams √ 134

Grease Rock Valve and Agitator Bearings √ 134

Inspect For Damage and Leaks √ 134

Check If Maintenance Is Due √ 134

Check Rock Valve Tension Nut √ 134

Inspect Cutting Ring/Rotate If Needed √ 135

Lubricate Mechanical Moving Parts √ 135

Check Unit Mounting Hardware √ 135

Check Hydraulic Pressures √ 135

Set Concrete Pump Pressure √ 136

Set Agitator Pressure √ 137

Clean Hydraulic Oil Cooler Fins √ 138

Change Hydraulic Oil For Temperature Reasons √ 138

Check the Pre-Charge Of The Accumulator √ 138

Change Hydraulic Oil For Age Reasons √ 142

Change Hydraulic Oil Return Filter √ 142

Maintenance


Unscheduled maintenanceThe following items will have to be maintained on yourpump. The time of service that you get from these partsvaries dramatically from unit to unit because of thewide range of applications to which these machines aresubjected. Differences in concrete and pressure play amajor role in the wear of these components.

Changing ramsWhen you begin to see not just cement dust in yourwaterbox at the end of the day, but also small bits ofsand or even pebbles, it is time to change the rams.

NOTE! When changing rams, you will have to putyour hands in the waterbox on several occasions. In thepast, we instructed you to stop the engine each andevery time before putting your hands into the waterbox,and we still highly recommend the practice.

However, If You Insist On Changing Rams WithThe Motor Running, You Must Take The FollowingPrecautions To Avoid Amputation Of Hands, ArmsAnd Fingers:

• Do Not Use The Remote Control For ThisProcedure! Unplug It And Store It.

• Do Not Allow Anyone Else At The PassengerSide Controls When You Are ChangingRams. The chances of accidental amputationare greatly increased if more than one person isaround. There are also less distractions whenyou are alone, so your attention will notbecome divided. If someone comes up, stopworking until they leave.

• Reduce engine r.p.m. to absolute minimum,and adjust the stroke limiter to minimumstrokes. The slower the hydraulic pumps areturning, the slower the differential cylinderrods will move. This buys extra time in casethe unexpected happens.

• Please do not skip any of the above steps. Ifyou leave the engine running, you are alreadyskipping the one step that makes an accidentimpossible.

Maintenance


To remove the old rams

Close the shut-off valve (Figure 73). This gives youcontrol over the direction of travel of the differentialcylinders.

Drain the waterbox. Remove the waterbox cover, andthe bolt down grate.

Retract the left side differential rod almost all the wayinto the waterbox (Figure 74). Leave about 1.5 inchesof travel, which will allow you to remove the spacercoupling (dogbone).

Push the emergency stop button on the operator’spanel. Stop the engine and put the key in your pocket(stopping the engine before putting your hands in thewaterbox is mentioned at every appropriate spot).

SWG98n197.eps

Figure 73Showing the concrete pump shut-off valve (dump

valve).

Figure 74Retract the left side rod into the waterbox all but about

an inch and a half

Maintenance


A 55 mm open end wrench and a 24 - 30 mm box endwrench were supplied with the unit. You will needthem for this step. Locate the 55 mm wrench on thedog bone to hold the assembly from turning. You can

rest the handle against the side of the waterbox asshown in Figure 75. Unscrew the 4 M20 bolts that holdthe assembly together.

Be sure all personnel and tools are out of the waterbox,then start the engine. Release the emergency stopbutton. Finish retracting the left side rod into thewaterbox. The dogbone will fall out.

Push the emergency stop button on the operator’spanel. Stop the engine and put the key in your pocket.Remove the dogbone from the waterbox as shown inFigure 76.

Start the engine. Release the emergency stop button.Slowly extend the cylinder rod until it just contacts therubber ram flange. Be Careful Not To Drive TheRubber Ram Into The Material Cylinder.

NOTE!If it happens that you accidentally knock theram into the material cylinder so far thatyou can’t reach it, you will have to remove itby knocking it out from the rock valve end

of the unit. Call the Schwing ServiceDepartment at (651) 429-0999 forinstructions on this procedure.

Figure 75Remove the bolts from the dog bone

Figure 76Remove the dogbone

Maintenance


Push the emergency stop button on the operator’spanel. Stop the engine and put the key in your pocket.There is a groove in the ram flange that will line upwith a groove in the cylinder flange. A 1/2 inch x 2 1/2inch bolt with nut will drop into this groove and allowyou to pull the ram out (Figure 77). The fit should besnug, but there’s no need to tighten the nut with tools,

and note that the ram flange and cylinder flange areshown outside of the waterbox for clarity of theillustration.

Start the engine. Release the emergency stop button,and slowly retract the cylinder rod until the ram is clearof the material cylinder (Figure 78).

Push the emergency stop button on the operator’spanel. Stop the engine and put the key in your pocket.Remove the nut and bolt, and the ram will be free tocome out of the waterbox.

Clean and inspect the bolts and cone washers, the dogbone, and the cylinder flange. Replace any damaged orworn parts with new ones.

Figure 77Showing the removal bolt grooves on the

flanges

Figure 78Slowly bring the ram into the waterbox

Maintenance


To install the new rams

Apply Loctite primer (or equivalent) to the M20 bolts.Allow the primer to dry.

While the primer is drying, apply a liberal coat of cleangrease to the new rams. There is no such thing as toomuch grease here, because the excess will be wiped offby the material cylinders during installation.

With the engine still stopped, hold the new ram up tothe cylinder flange. Line up the grooves, and drop yournut and bolt into place to hold the assembly together.Again, you should only tighten the nut finger tight.

Start the engine. Release the emergency stop button.Slowly extend the cylinder until the ram is installed inthe material cylinder, but the mounting flange is stillexposed enough to remove the nut and bolt (Figure 79).

Push the emergency stop button on the operator’spanel. Stop the engine and put the key in your pocket.Remove the nut and bolt.

Start the engine. Release the emergency stop button.Slowly retract the rod again, until there is room toinstall the dog bone.

Push the emergency stop button on the operator’spanel. Stop the engine and put the key in your pocket.Apply Loctite 242 or equivalent to 2 of the M20 bolts.Place the dog bone up against the flange of the newram. Install 2 of the M20 bolts (with Loctite) And TheCone Washer Sets. At this time finger tighten only.

NOTE!It is important to install the dog boneagainst the new ram first, not the cylinderflange. This gives you an extra 6 to 8 inchesof safety margin when you extend thecylinder to meet the dog bone. If you attachto the cylinder flange first, chances are goodthat you will accidentally knock the newram into the material cylinder so far thatyou won’t be able to reach it. See point forinformation on this problem.

SWG98n214.eps

Figure 79Slowly push the new ram into the material cylinder

Maintenance


Start the engine. Release the emergency stop button.Slowly move the cylinder down to where it’s flangebutts up to the dogbone. Be careful not to go too far(Figure 80)!

Push the emergency stop button on the operator’spanel. Stop the engine and put the key in your pocket.You may have to slightly rotate the dog bone to alignthe bolt holes with the cylinder flange. When aligned,coat the 2 remaining M20 bolts with Loctite and install,including the cone washer sets. Once all 4 bolts arestarted, you may tighten the bolts to the torque spec forM20 10.9 bolts (420 ft/lbs).

Repeat the previous steps for the right side ram.

Open the shut-off valve. Note that the unit will notcycle with this valve closed.

Changing the Material Cylinders.

The material cylinders eventually wear out. They areconsidered worn out when the chrome starts to wear offthe barrel. Normally, the end attached to the RockValve wears out first, because it sees the most concrete.The waterbox end may be in like-new condition,because that end never experiences concrete. For thisreason, the material cylinders were designed to be ableto flip end for end. That way, you can move the wornout part to the waterbox, and the like-new part to theconcrete valve for double the life. If you are going todo this, you have to catch the wear on the materialcylinders before they get too thin or break through inone or more spots. Once that happens, you cannot flipthem, because they will be structurally too weak tohold the pressure forces at the waterbox end.

The procedure for changing and aligning the materialcylinders is the subject of Service Bulletin G-102/88.Contact the Schwing Service Department at (651)429-0999 or 678-560-9801 if you need a copy of thebulletin.

Figure 80Slowly move the cylinder to meet the dog bone

Maintenance


NOTES

Appendix

Line pumpsStartup 250:Users:Danny:Desktop:Operation manuals:small line:All SP Rock Valve models:Frame files:Appendix.fm Operation Manual - 151

APPENDIXHydraulic Oil Viscosity Chart .................................................................. 152Torque Specifications for Metric Bolts..................................................... 153Recommended Emergency Hose Kit...................................................... 154Fitting Wrench Sizes ............................................................................... 155Maintenance checklist ............................................................................ 156Nomograph ............................................................................................. 163Weld On Ends / Coupling Comparison ................................................... 171MInimum Pipe Wall Thickness ................................................................ 172Decal Location Guides............................................................................ 173Glossary of Terms................................................................................... 180Additional Reading Material.................................................................... 185List of Lubricants and Nitrogen............................................................... 186Hydraulic Schematics ............................................................................. 190Nomographs ........................................................................................... 201Output Charts ......................................................................................... 208

swg99a001.eps

Appendix


AppendixThe Appendix contains the technical documentation ofyour machine and its systems. This documentation iscorrect for your machine when it left the factory, but itmay need to be updated from time to time.

Hydraulic Oil Viscosity ChartThe chart below shows the relationship between the oiltemperature and its viscosity. As you can see, the oilgets thicker when the temperature is low, and thinner asthe temperature rises.

• The cold start limit represents the coldesttemperature at which the oil is thin enough toflow into the hydraulic pumps. Anythingcolder, and the pumps would not be able tosuck the oil (cavitation).

• The minimum permissible viscosity representsthe warmest temperature at which the oil willstill be thick enough to provide lubrication andsealing. Anything warmer, and the componentswill have metal to metal contact (thermalbreakdown).

• The optimum operating viscosity is the rangeof oil thickness where the oil will work thebest (thin enough to flow easily, thick enoughto protect the system components).

For an example of how to read the chart, look at therange for VG-46 oil below. The chart shows the coldstart limit as -8° C (18° F), and the minimumpermissible viscosity as 90° C (194° F). The optimumrange is at about 50° C to 76° C.

Appendix


Torque Specifications for Metric BoltsThe following charts show the tightening torquesspecified for the bolts used on Schwing equipment. Thecharts are to be followed unless there is different torquespec. indicated for a particular procedure.

Torque specifications are very important for propermachine function. For further information on thissubject, see the section on bolt tightening in theMaintenance section of this manual.

.

1. Nuts and Bolts as per DIN 912 – 931 – 933 – 934 – 6914 - 6915 Applicable to: 1. Geomet/Dacromet 500 coating.

2. Black and silver-chromated nuts and bolts fitted with mounting paste such as Cu or MOS2.

Assuming a friction coefficient of µ = 0.1.

Coarse-Pitch Thread Fine-Pitch Thread * Fitting Tightening Torque (Nm, ft lb) * Fitting Tightening Torque (Nm, ft lb)

Grade Grade

Bolt SizeBolt Size

8.8 10.9 12.9 8.8 10.9 12.9

T

hrea

d

Des

igna

tion

N m ftlb

N m ft lb N m ft lb

T

hrea

d

D

esig

natio

n

N m ftlb

N m ft lb N m ft lb

M 4 X 0.7 2.2 1.6 3.2 2.4 3.8 2.8 M 8 X 1 20 15 28 21 33 24

M 5 X 0.8 4.3 3.2 6.4 4.7 7.5 5.5 M 10 X 1 40 29 57 42 68 50

M 6 X 1 7.5 5.5 10.8 8 12.6 9.3 M 10 X 1.25 37 27 55 41 64 47

M 8 X 1.25 18 13 27 20 31 23 M 12 X 1.25 67 49 100 74 115 85

M 10 X 1.5 36 27 53 39 62 46 M 12 X 1.5 65 48 95 70 110 81

M 12 X 1.75 62 46 90 66 108 80 M 14 X 1.5 105 77 155 114 180 133

M 14 X 2 100 74 140 103 170 125 M 16 X 1.5 160 118 235 173 280 206

M 16 X 2 150 111 225 166 260 192 M 18 X 1.5 240 177 345 254 400 295

M 18 X 2.5 220 162 310 228 365 269 M 20 X 1.5 335 247 475 350 590 435

M 20 X 2.5 300 221 440 324 510 376 M 20 X 2 560 413

M 22 X 2.5 420 310 590 435 700 516 M 22 X 1.5 460 339 650 479 750 553

M 24 X 3 530 391 750 553 880 649 M 24 X 2 560 413 810 597 940 693

M 27 X 3 780 575 1120 826 1300 958 M 27 X 2 820 604 1170 862 1390 1025

M 30 X 3.5 1080 796 1530 1128 1750 1290 M 30 X 2 1170 862 1660 1224 1930 1423

M 36 X 4 - - **2000 **1475 - -

* The fitting tightening torque corresponds to the axial force in the bolt at which the limit of elasticty of the latter is utilised 90 % by tension and torsion.

** only Octagonal column 12_09

Appendix


Recommended Emergency Hose KitWe recommend that you carry one of each of thefollowing hoses on the unit for use if you would blow ahose on the job. Each size listed represents the longest

hose of each diameter that is installed on the unit in thefactory. Keep the inside of the hoses clean until neededby capping the ends and taping the cap into place. Dirtintroduced into your hydraulic system by installing ahose that was not kept clean will cause a variety ofproblems in the operation of the unit.

NOTE: Bolt head identification marks are shown as per grade. Manufacturerís marks may vary.

Use the values listed unless special torques are specified. Values are for UNC and UNFthread fasteners. Values do not apply if graphite, moly-disulphide or other extreme pressurelubricant is used.

GENERAL SAE BOLT TORQUE SPECIFICATION TABLE

5SAE GradeNumber 8

Bolt headidentificationmarks. SeeNote below.

Bolt Size lb.-ft N•m lb.-ft N•m

1/4” 9-11 12-15 12-15 16-205/16” 17-20.5 23-28 24-29 33-39

61-733/8” 35-42 48-57 45-547/16” 54-64 73-87 70-84 95 -114

1/2” 80-96 109-130 110-132 149-179217-260160-192149-179110-1329/16”

5/8” 150-180 203-244 220-264 298-3583/4” 270-324 366-439 380-456 515-6187/8” 400-480 542-651 600-720 814-9761” 580-696 787-944 900-1080 1220-1464

1-1/8” 800-880 1085-1193 1280-1440 1736-19531-1/4” 1120-1240 1519-1681 1820-2000 2468-27121-3/8” 1460-1680 1980-2278 2380-2720 3227-36881-1/2” 1940-2200 2631-2983 3160-3560 4285-4827

Diameter Length Part Number

8 1000mm 1005017410049906100499431004996230347674

13 1200mm16 800mm20 1250mm

WPhose lengths.eps

25 1100mm

Appendix


Fitting Wrench SizesThis chart is provided as an aid to selecting the properwrench to hold or tighten the hydraulic fittings foundon Schwing equipment. Sizes may change, use only asa guide.

Straight Fittings

Banjo Fittings

Appendix


Maintenance checklistThe following is the normal recommendedmaintenance schedules (after the break in period).

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Check Engine Fluid Levels √ 133

Check Tires √ 133

Check Hydraulic Oil √ 133

Bleed Moisture From Hydraulic Tank √ 133

Check Differential Cylinder Rod Packings √ 133

Inspect Bolts On Rams √ 134

Grease Rock Valve and Agitator Bearings √ 134

Inspect For Damage and Leaks √ 134

Check If Maintenance Is Due √ 134

Check Rock Valve Tension Nut √ 134

Inspect Cutting Ring/Rotate If Needed √ 135

Lubricate Mechanical Moving Parts √ 135

Check Unit Mounting Hardware √ 135

Check Hydraulic Pressures √ 135

Set Concrete Pump Pressure √ 136

Set Agitator Pressure √ 137

Clean Hydraulic Oil Cooler Fins √ 138

Change Hydraulic Oil For Temperature Reasons √ 138

Check the Pre-Charge Of The Accumulator √ 138

Change Hydraulic Oil For Age Reasons √ 142

Change Hydraulic Oil Return Filter √ 142

Appendix


Output chartsThe hydraulic pumps that drive your concrete pump arehorsepower controlled. That means that when pressurerises past a certain point (known as the breakpoint), thepumps will change their displacement per revolutionresulting in less flow and less strokes per minute. Thereason for this is so the pumps will not stall yourengine by drawing too much horsepower. Output chartsshow the horsepower curve (in kilowatts, or KW) ofthe concrete pump hydraulic circuit. From them, youcan determine:

• the maximum concrete pressure of the pumpkit model.

• the maximum output (in cubic yards per hour)of the pump kit model.

• the maximum strokes per minute of your pumpkit model.

• the maximum output (in liters per minute) ofyour hydraulic pumps.

• the output that can be expected at variouspumping pressures.

• the condition of your hydraulic pumps (whenused in conjunction with a flow meter).

• the break point of your hydraulic system.

An explanation of an output chart is shown in the chartfollowing, by some examples of chart usage. Theoutput chart of the pump kit shipped with this manualis shown in the Appendix..

Appendix


Using the chart.Example 1, checking flow at a given pressure: Yourunit is configured on the rod side (standard from thefactory). You notice that your machine is not getting asmany strokes per minute as you are used to seeing. Youcount the strokes and see that you are getting about 211/2 per minute. You check your pressure gauge and seethat the hydraulic oil pressure is at 220 bar.

To determine if your unit is acting normally: Locate the220 bar oil pressure marking on the rod side scale (itemA in the example below). Next, you draw a line straightacross the page until you intersect with the horsepowercurve (item B in the example below). Draw a straightline down from the intersection point until you passthrough the rod side number of strokes scale, and readthe strokes per minute. At 220 bar you should begetting a little more than 21 strokes per minute. Yourunit is fine.

Appendix


Example 2, checking your hydraulic pumps. Todetermine if your pumps are still in good workingcondition, you use the output chart and a flow meter.You test one pump at a time, multiply the readings by2, and chart the result. You multiply the readingsbecause the chart is based on the output of two pumps,but we are only testing one at a time. To test yourpumps:

• Be sure that you are using the chart that appliesto your unit.

• Be sure to set the RPM to the correct setting.Even a few RPM difference will give you a badreading. Check it with a digital tach, if one isavailable.

• Be sure that you know how to use your flowmeter. Read the instructions that came with it.Flow meters must be calibrated periodically.

• Make 2 copies of the output chart, so you don’truin your original. You need one chart for eachpump tested.

Read the flow at 0 bar, 100 bar, 150 OR 200 bar, 250bar, and 300 bar. You also document the breakpoint.The breakpoint is where the flow drops off rapidly. Youwill be able to notice it on the flow meter. If you thinkit would be helpful, copy the chart below. Check whichreading (150 or 200 bar) you used. The breakpoint willbe very close to either 150 or 200 bar, so it’s notnecessary to take them both. The breakpointspecification is shown on each output chart.

As an example, we’ll pretend that we have just takenthese readings:

Appendix


The next step would be to plot the readings on theoutput chart. Take one of your clean out put chartcopies and proceed as follows:

• Lay a straight edge (a ruler or similar device)horizontally across the page, at the pressurepoint that you are plotting. Make a light lineacross the chart. In the example below we areusing the rod side scales and curve (you coulduse the piston side scale and curve instead).The ruler is shown ready to draw a line at 250bar hydraulic pressure.

• Turn the ruler sideways and draw a light lineup the page from the liters/minute reading youtook at that pressure (don’t forget to multiplythe reading by 2). In our example, wemeasured 276 liters at 250 bar.

• At the point where the two lines intersect, put adot.

• Do the same thing with each pressure reading.You should end up with 6 dots.

Appendix


Next, connect the dots. If your plotted line reasonablymatches the specification plot on the chart, the pump isOK. If your line is to the lower left of the spec, thepump is getting weak. If your line is to the upper right

of the spec, you’ve done the test incorrectly, or you areusing the wrong chart. In our example, the pump is OK(see the plot below).

Next we need to check the 2nd pump. We hook up theflow meter just as when we checked the first pump.Again, be sure that you have the correct speed, gear,chart, etc. This time our example will have worseresults.

Appendix


Again, plot the results on a clean copy of the flowchart.As we plot this pump, we can see that the dots aremoving quite a bit to the inside of the flow specification(see the chart below).

When you connect the dots, the line is completelybelow the specifications. This pump is very weak, andwill completely stop pumping oil soon. You may noticehigh heat with this unit, if you are pumping at high oilpressures. NOTE! Never try to make up for this weakpump by increasing the speed of the engine. As thepump turns faster than specification, it will not be ableto suck oil as fast as it is turning (it is called“cavitation” if this happens), and immediate failurecould result.

If the plotted curve matches the spec for a while, butthe breakpoint is too high or too low, it is possible tomake an adjustment. Contact the Schwing ServiceDepartment for the procedure.

There are many different possible pump kits and powersettings for each unit. If you accidentally destroy youroriginal output chart, please have your serial numberhandy when you call to get a replacement. Also, pleaseadvise us if you have changed differential cylinders,

material cylinders, or hydraulic pumps, because youmay need a different output chart than the one that wasoriginally shipped with the unit.

Appendix


Nomograph

Using a Nomograph

General Information

Concrete pumps are limited in what jobs they can doby 3 things:

1. The amount of power available,

2. The maximum concrete output available, and

3. The maximum concrete pressure available.

To determine the suitability of a particular pump for aparticular job, a tool is needed to estimate the powerrequired by the job. The nomograph is this tool.

In the case of a concrete pump that is driven by it’s ownprime mover, such as a trailer mounted concrete pump,or a truck mounted pump with separate drive engine,the power rating (in Kw) is shown for the engine orelectric motor. In the case of a truck mounted pumpthat uses a PTO from the truck engine, the power ratingreflects the power output of the hydraulic pumps only(all the power from the truck engine is normally notavailable to the concrete pump and should not be usedfor power calculations).

Assuming that you know the required output for thejob, the nomograph will help you to calculate therequired pressure. With known output and pressure, thepower requirement can be found. The nomograph wasdeveloped by extensive trial and error testing and hasproven to be accurate to within ±10% in nearly allpumping applications. The original nomographs used“spread measure” of fresh concrete instead of slumpand the two are not directly interchangeable. Intranslating the charts from spread measure to slumpsome approximations are used, but the ±10% accuracywill still apply. In all cases it is assumed that you willreceive fresh, quality concrete on your job, and that theconcrete will be plastic enough to flow into the materialcylinders. If you know that the concrete will be hard tofeed into the cylinders you should adjust the outputrequirement to compensate for incomplete filling. Forexample, if you will need 50 cubic yards per hour intothe form but the concrete is so stiff that it will onlyprovide 80% filling of the cylinders, then you shouldmultiply the output required by 1.25.

The nomograph is divided into 4 quadrants.

Figure 81 Quadrants

Appendix


The upper left quadrant is the beginning and end pointof the graph, and shows maximum output, pressure andpower for a specific machine. The upper right quadrantaccounts for the relationship between output ofconcrete and pipeline diameters. The lower rightquadrant accounts for the resistance to flow of theentire pipeline system, and the lower left quadrantaccounts for the pumpability of the concrete.

To use the nomograph, you begin at output requiredand move in a clockwise direction until you encounterthe lines that represent your job situation. Each timeyou meet the line that applies, you make a 90° turnuntil you come to a point on the bottom of the upperleft quadrant that shows pressure required (Figure 82).

To illustrate the use of a nomograph, we will use ahypothetical job situation with the followingspecifications:

• We will need an average output of 45 cubicyards/hr, but we will be pumping only 75% ofthe time. The rest of the time will be spentmoving hose, removing pipe lengths, waitingfor concrete trucks, etc. This means that whenwe are actually pumping, we will need an

output rate of 45 ÷ .75 = 60 yd3/hr.• We will use 5" diameter pipeline for our job.• We will have the following pipeline lengths: 30

ft. horizontal, 1 long sweep elbow, 250 ft.vertical, 2 long sweep elbows, 150 feethorizontal, 40 feet of 5" rubber hose.

• We will specify a slump of 3-4", and use the 3"line on the chart.

• In addition, when we add the pressure for thevertical run we will have to add 1.1 times 250ft. = 275 PSI.

All of these criteria will be explained in detail as we gothrough the individual quadrants.

A Description of the Quadrantsa. The upper left quadrant describes the power

curve of a given Kw rating, and the maximumflow and maximum pressure of a particularconcrete pump.

Figure 82Moving around a nomograph

Appendix


Any concrete pump selected for a certain job mustmeet 3 technical parameters:

1. The TK number of the pump must be equal to orgreater than the TK number of the job,

2. the maximum output required by the job must beavailable from the pump, and

3. the maximum pressure required by the job must beavailable from the pump.

It is important to notice the pump max. pressure andmax. output even if the TK of the pump is larger thanthe job requirement. An example of the reason for thisis illustrated in point #3 below. These parameters aredecided during the design stage of the unit and cannotbe adjusted on the job. If the unit has the ability to gofrom rod side to piston side, maximum pressure andoutput can be exchanged, that is you can decrease onewhile increasing the other an equivalent amount.

1. The Technical Identification Number(abbreviated as TK) is the Kw multiplied by25, and the number 25 is a constant that hasseveral efficiency factors figured in. Whenusing a metric nomograph (pressure in bar andflow in cubic meters per hour), the pressuremultiplied by the flow will always directly

relate to the TK. For example, if you needed 50cubic meters/hour and determined that this willrequire 60 bar you can multiply 50 x 60, whichequals 3000. Any pump you select must have aTK of 3000 or greater. If you are using anomograph that has been converted toAmerican units of measure (pressure in PSIand flow in cubic yards/hour) you can stillmultiply the pressure times the flow, but youmust divide the answer by the conversionfactor between metric and US units of measure

to get the TK. The conversion factor for yards3

to meters3 and bar to PSI is 18.966. For allpractical purposes you can use 19. Forexample, if you need 60 cubic yards/hour anddetermine that your job set-up will require 950PSI, you can multiply 60 x 950, which equals57,000. Divide this by 19 and you find thatyour TK requirement is 3000. Again, anypump you select should have a TK of 3000 orgreater.2. The Maximum Output (abbreviated as

max Q) is determined by the size of thehydraulic pumps, the number of strokes perminute and the size of the differential and

Figure 83Upper left quadrant

Appendix


material cylinders. Usually, the unit isdesigned so maximum output can be achievedonly at less than maximum pressure.3. Maximum Pressure (abbreviated as max

P) is determined by the size of the differentialand material cylinders and the setting of themain relief valve. To be sure that the unit willhandle the job be careful to notice max P andmax Q. Here is an example of why that isimportant. You only need 20 yards/hour, butyou calculate that you will need 1900 PSIpressure. The TK of this job is 2000. The pumphas a TK of 2775, so there is enough poweravailable, BUT... the maximum pressureavailable from the pump is only 1570 PSI. Thispump wouldn’t do the job.

b. Follow the chart in a straight line fromrequired output into the upper right quadrantuntil you come to the size of the pipeline thatyou will use. A good rule of thumb for sizingpipeline is to use the largest diameter pipelinethat you can. It takes less force to moveconcrete through a 6" pipeline than, forexample, a 4" pipeline. When pressure isexerted on concrete in a pipeline, a paste ofwater and cement fines coats the inside of thepipeline and forms a slippery layer on which

the bulk of the concrete slides. While it is truethat a 6" pipeline has more surface area to coatthan a 4" pipeline (49% more), the volume ofconcrete that can move on the layer isincreased by 125% which results in lowervelocity of the concrete (in feet per second),lower friction, and therefore lower pressure. Apump that may not be capable of completing adifficult job through 4" or 5" pipe may verywell be able to do it through 6" pipe.

NOTE!Experience has taught us that 5" is theoptimum pipeline size for lengthy verticalruns such as those found on a high risebuilding. It is large enough for mostaggregate, but small enough that youminimize backers when the concrete valvecycles. You must also consider the men atthe point of placement. There are very few,if any, hose men that can move 6" hose on aslab all day. There is no provision in thenomograph for mixing pipeline sizes. Forexample, if you will be reducing from 5" to4" pipe you should calculate the chart as ifyou were using 4" pipe for the entiredistance. This will not be completelyaccurate, but you will be safe in yourpressure calculation. In our example, wewill use 5" pipeline (Figure 84).

Figure 84Upper right quadrant - Pipeline diameter

Appendix


When the output line intersects the pipeline diameterthat corresponds to your job, you should draw a linestraight down into the lower right quadrant, as shownin Figure 84.

c. The lower right quadrant refers to theproportional value of your pipeline. It is a wayof taking into account not only the length ofthe pipeline, but also the amount of bends, theincreased resistance of flow in rubber hose, etc.It is more a measure of the resistance to flowthan a length measurement. To calculate theproportional value of your pipeline, thefollowing criteria will apply:

• each 90° bend with a radius of 250 mm (boomelbow) = 3.5 feet

• each 90° bend with a radius of 1 meter (longsweep) = 10. feet

• each 30° or 45° bend with a radius of 1 meteror 250 mm = 3 feet

• each section of rubber hose causes 3 times asmuch resistance as the same length of steelpipe (e.g. 12 feet of rubber hose has the sameresistance as 36 feet of pipeline).

• all distances should be figured equally whetherthey are horizontal and vertical. The increasedpressure required to push concrete vertically isaccounted for by adding pressure, not distance.Our example pipeline is shown below (Figure85).

.

Figure 85Calculating Proportional Values

Appendix


Once you have calculated the proportional value ofyour pipeline, you can extend your line down from theupper right quadrant until it intersects with the line thatrepresents your pipeline. When you reach the

intersection, make a 90° turn clockwise, into the lowerleft quadrant. As noted above, we will use 600 feet asour proportional value (Figure 86).

d. The lower left quadrant refers to thepumpability of the concrete. If the concretespecifications allow a range in slump (forexample 3 - 4"), you should always use thelower end to be safe. In our example, we use 3"

slump. You extend the line from the lower rightquadrant until it intersects with the 3" slumpline, then make a 90° turn clockwise, whichwill lead you back into the upper left quadrantthrough the pressure scale (Figure 87).

Figure 86Lower right quadrant - Proportional Value of

Pipeline

Figure 87Lower left quadrant - Pumpability of the Concrete

Appendix


As you can see by the chart in Figure 87, we are re-entering the upper left quadrant through the pressurescale at about 650 PSI. Remember, we now have to addthe head pressure for our vertical rise. At 1.1 PSI perfoot of level difference, and our 250 foot vertical run,we must now add 1.1 x 250 = 275 PSI to the 650 PSIfrom the chart.

650 PSI+ 275 PSI = 925 PSINOTE!

When calculating the head pressure fromvertical runs, it doesn’t matter if thepipeline runs straight up and down, or if itruns uphill at an angle. Only the leveldifference in feet is needed for the pressurecalculation. If the pipeline is running

downhill the operator will need specialknowledge, but you don’t need to add anyhead pressure to the nomograph.

The nomograph is now complete. The TK of our jobcan be calculated like this:

TK = (PSI x yd3/hr) ÷ 19We need a unit that is capable of 925 PSI, and 60 yd3/hr. The TK of this job is:

TK = (925 x 60) ÷ 19TK = 55,500 ÷ 19

TK = 2921The unit must have a TK of over 2921 and it must beable to pump 60 yd3/hr and 925 PSI Simultaneously.Look at the pump shown in our sample nomograph(Figure 88).

• Can the unit pump at 925 PSI - YES• Can the unit pump 60 yd3/hr? - YES• Can the unit pump both simultaneously? - NO!

This unit will not do the job.

The engine is a little bit too small. The intersection of60 yards3/hr and 925 PSI has been plotted for visualrepresentation, but you can see immediately that theTK of the job (2921) is bigger than the TK of the unit(2775). The curved black line represents the TK of theunit. If the unit is going to be able to handle the job, the

intersection of pressure and yds3/hr will be to the rightand down from the curved line. Anything to the left orabove the line is beyond the power of the engine. Whatif we could order this same unit with a slightly biggerengine? The TK of the bigger engine is 3300. Thisshould work. Plotting the intersection of ourhypothetical job again, you can see that it falls withinthe power zone of the engine (Figure 89).

Figure 88Is this unit sufficient for the job?

Appendix


Bearing in mind that the nomograph should only beconsidered accurate to within ± 10%, you shouldalways calculate conservatively, and allow for thegraph tolerance. In the case of the pump in Figure 89,we should still be safe even if the pressure requiredwere 10% greater (1017 PSI).

What if you already own the pump shown in Figure88? Is there anything that can be done to the jobspecifications to make the pump with the smallerengine work? You could use the smaller TK unit shownif Figure 88 if you can get an OK to do any of thefollowing things:

• Pump the top of the building at 50 yd3/hr

instead of 60 yd3/hr.• Pump the top of the building at a 4" slump

instead of 3" (this would still be withinspecifications).

• Remove some of the rubber hose at the end ofthe horizontal run.

With job circumstances that did not require asubstantial vertical run, you could also use 6" insteadof 5" diameter pipeline.

Figure 89Same model pump with a bigger engine.

Appendix


Weld On Ends / Coupling Comparison

Heavy Duty

Metric

Grooved(Victaulic)

Male / FemaleO-Ring(shown with clamp)

weldends4.eps

≤ 0.15"

NOTE: All pressure ratings listed refer to 5 inch (125mm) diameters in like-new condition. Other pressures would apply to other sizes.

3. Metric couplings are designed for pressures up to1400 PSI @ 2:1. They have 85% more contact areathan grooved couplings. The face is flat and will notdraw pipe together. Although they have a raisededge, they are not compatible with Heavy Duty cou-plings unless a special clamp or an adapter pipe isused to change from one style to the other. Metricconnections are standard equipment on boomsbecause of the weight savings compared with otherstyles.

2. Heavy-Duty couplings are designed for pressuresup to 2250 PSI @ 2:1. They have 20% more contactarea than metric couplings, and a tapered face thatdraws the pipe sections together during assembly.Both the ends and clamps weigh more than metricstyle, and therefore should not be used on boomswithout consulting the manufacturer.

1. Male / female o-ring type couplings have thehighest pressure rating of the ends commonly usedfor concrete pumping. They can withstand 4350 PSI@ a 2:1 safety factor. They are self aligning andwaterproof when used with o-rings in good condi-tion. Typically not used on booms because of theirweight. Pipes equipped with this style couplingcannot be swapped end-for-end.

4. Grooved couplings (lip height of 0.15” or less)are designed for pressures only up to 750 PSI @2:1. The recessed groove is hard to clean whenchanging pipe on a job. The weld-on end failsbefore the pipe because the groove is cut into thepipe thickness, making it the weakest spot. Groovedcouplings are not recommended for concrete pump-ing applications.

Shown is a comparison among commonly usedends/couplings. No two ends shown can be joinedwithout the use of an adapter pipe or a specialadapter clamp. Clamps and pipe strength must alsobe considered when determining proper systemrequirements. The ratios shown in the text belowrepresent the safety factor from burst : working

Appendix


MInimum Pipe Wall Thickness

PIPE WALL THICKNESS

0.025"

.050".075"

.100".125"

.150".175"

.200".225"

.250".275"

.300".325"

.350".375"

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

3400

3600

3800

4000

4200

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

SCHEDULE 40(1/4 wall)

9 gauge 3/16”11 gauge 7 gauge

MAT

ER

IAL

PR

ES

SU

RE

BARPSI

1. This chart assumes a safety factor of 2:1. Higher safety factors may be required in some circumstances.2. Wear reduces wall thickness. Thickness must be checked on a regular basis.3. Pressures may be limited even more by clamp style or pipe end used.4. The chart is based on 62,000 PSI tensile strength. Heat-treated calculations are based on 120,000 PSI tensile strength.5. The chart is for pressure calculations ONLY. There is no allowance for mechanical forces other than pressure, and thicker

walls may be needed for mechanical strength because of support or restraint considerations.6. The chart does not take into account metal fatigue caused by pressure cycles.

Note! This chart is intended as a guide for concrete pumping applications and is subject to the notes, assumptions, and conditions listed above. Any other use of this chart is not recommended.

This chart does not apply to double-wall pipe. Double wall pipe can be checked by inspecting the inside of the pipe. If the insert is intact, the pipe is okay. If the insert is worn through, the pipe must be replaced. Contact your pipe supplier for the pressure capacity of your double-wall pipe.

pipe

wal

lvsP

ress

2.ep

s

.heat treated .standard

4“ H

EAT

TREA

TED

5“ H

EAT

TREA

TED

6“

HEA

T TR

EATE

D

4.8”

& 4

.9“ H

EAT

TREA

TED

4.4”

HEA

T TR

EATE

D

4.9“ (7, 9

, 11 gauge) s

ystem

(125 m

m)

6“ syste

m

5“ syste

m 4.0

“ sys

tem

4.4“ sys

tem

4.8“ syste

m

0.12

0”

0.15

0”

0.17

7”

0.18

8”

0.25

0”

Minimum Pipe Wall Thickness As a Function of Pressure

Appendix


Decal Location Guides

BPA 450 and 500 units

30336985

30309999C

30333578 30390162

30390161

30390145

30332668B

30324599B 30390146

30390772 30390771

30390772

30390550 (450)30390538 (500)

30334976

30336983A

30312146A30336985

30390162

30392275

30319867A30309999C

30332668A

30390161

30308020B30301733F3039056630319872B

30390145

30333268

30390507

3039077230390771

30390772

30335000A

30306123C

30394069 30390550 (450)30390538 (500)

30392275

30396340

30354742

30363631

30354742

30364520A

30364521

30363822

30364520A

30364521

30365188

3036956230369563

30363822

30362340

30340149A

450_500decals.eps

Appendix


BPA 450 and 500 units (continued)

30337004A(SLEWINGCYLINDER)

30309998B

30392272

30319872B(WATERBOX

COVER)

30390207

30309998B

30307689

30390179

30319869B

30307386B

3039077030390771

30337004A(WATERBOX)

30396340

30350290(FENDER)

30350290(FENDER)

30337004A(BPA 500)

ENGINEMAINTENANCE

30355137

30309998B

30354742A

3039077130363739

30364522

30340149

30332962

30363822

30309999C

30355887CPMA

30354742A

30332963

450_500decals2.eps

Appendix


WP 750 and 1000 units

30336985

30390771

30312146A

30390566 30301733F 30308020B

30390161

3039017830332668B

30309999C

30319867B3039077230390771

30336983A

30392275

30390771

30390772

30307386D30333578

30309999C30390161

30390566

30336985

30390771

30306123C

30394069

ENGINEMAINTENANCE

WATERCOOLANT

MAINTENANCE

30364520A

30364521

30364520A

30364521

30354742A

30354742A

30319875

3036363130363633(IF REQ)

30333268 30335000A

30390554 WP750-15X30390555 WP750-18X30390356 WP1000X30390351 WP1000XHP

30362340

30363822

30390554 WP750-15X30390555 WP750-18X30390356 WP1000X30390351 WP1000XHP30390178

30390207

30396340

30365188

30390507(IF REQ)

30340149A

30302078C

2”3-1/2”

DIMENSIONS ±1/4” (.25)

2-3/8”

2-3/8”

2”

2-1/4”

2-3/8”

3-1/2”

750_1000decals.eps

Appendix


WP 750 and 1000 units (continued)

30319869B

30390771 30307689

30390179

30309998C

30390770(IF REQ)

30334976B

30307386D

30363739

30364522

30309998C30319872D

30319872D

30337004A

30392272

(FENDER)

30392921(FENDER)

30334976B

30355137

30354742A

30309998C

30363822

30340149

30324599C

30355137

30355137

30309999C

30355887 30354742A

30390771

30396340

30319872D

3033296330332962

750_1000decals2.eps

Appendix


BPA 2000 units

1

2

34

5 6 9 10

11

12 13

1415

161718

19

20

22

23 24

5051

51

14

10

1

5051

5118

21

8

26

7

31

31

31 31

12 13

41

42

42

41

4748

Appendix


BPA 2000 units (continued)

27

29

38

39

3534

40

29

7

5050

37

30

32

33

28

36

28 36

35

27

27

25

31

24

43

44

45

46

41

49

Appendix


BPA 2000 units (descriptions)

Pos. Qty. Description Part No.1 2 SAFETY INSTRUCTIONS, HOPPER GRATE 30336985. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1 WARNING, EYE/EAR PROTECTION 30336983A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1 WARNING, DO NOT OPERATE WITHOUT TRAINING 30335000A. . . . . . . . . . . . . . . . . . . .4 1 IMPORTANT, ORDERING INFORMATION 30333268. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1 CONCRETE PUMP SEE MFG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 1 ACCUMULATOR SEE MFG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 2 TEXACO OIL SPECIFICATION 30396340. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 1 HYDRAULIC OIL ONLY, (SMALL) 30392275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 1 WARNING, IN CASE OF BLOCKAGE 30319867B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 2 WARNING, REMOTE CONTROL 30309999C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1 THROTTLE SEE MFG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 2 SCHWING 30390178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 2 BPA 2000 30395948. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 2 MADE IN USA 30390161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 1 DEUTZ ENGINE MAINTENANCE SEE MFG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 1 PATENT 30308020B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 1 SERIAL NUMBER PLATE 30301733F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2 DIESEL ONLY 30390566. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 1 SAFETY INSTRUCTIONS, ACCUMULATOR 30394069. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 1 SAFETY INSTRUCTIONS 30312146A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 1 WARNING, EXCESSIVE PRESSURE 30306123C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 1 ACCUMULATOR SAFETY RULES 30332668B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 1 EMERGENCY STOP 30333578. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 3 CHANGE FILTER SCHEDULE 30307386D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 1 WARNING, ACCUMULATOR EXPLOSION HAZARD 30324599C. . . . . . . . . . . . . . . . . . . . . .26 1 DEUTZ WATER COOLING INSTRUCTIONS SEE MFG. . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 3 WARNING, GRATES 30309998C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 2 WARNING, RETORQUE LUG NUTS 30350290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 2 WARNING, DO NOT PUT HANDS IN WATER BOX 30319872D. . . . . . . . . . . . . . . . . . . . . . .30 1 WARNING, SAFETY GUARD IS MISSING 30337004A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 5 WARNING, STAND CLEAR OF OUTRIGGERS 30302078C. . . . . . . . . . . . . . . . . . . . . . . . . .32 1 PARTS AND OPERATION MANUAL 30390207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 1 HYDRAULIC OIL ONLY, (LARGE) 30392272. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 1 VIN PLATE 30390770. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 2 SCHWING 30390179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 2 WARNING, STORED HYDRAULIC ENERGY 30334976B. . . . . . . . . . . . . . . . . . . . . . . . . . . .37 1 PARKER ACCUMULATOR -- MODIFIED 30390146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 1 WARNING, KEEP HANDS OUT 30319869B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 1 ROCK VALVE TM 30307689. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 1 TAG, DO NOT OPERATE, BILINGUAL 30332962. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 3 WARNING, STOP AGITATOR 30354742. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 2 WARNING, KEEP HANDS AWAY FROM HYDRAULIC CYLINDER 30364521. . . . . . . . .43 1 WARNING, DO NOT INSERT SOLID 30355137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 1 WARNING, DO NOT BRING REMOTE CONTROL NEAR WATERBOX 30363822. . . . . .45 1 WARNING, KEEP HANDS OUT OF CONCRETE VALVE 30363739. . . . . . . . . . . . . . . . . .46 1 WARNING, ACCUMULATOR EXPLOSION HAZARD 30364522. . . . . . . . . . . . . . . . . . . . . .47 1 AGITATOR 30363631. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 1 WATER PUMP 30363633. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 1 EMERGENCY STOP 30340149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 6 REFLECTOR, RED 30390771. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 2 REFLECTOR, AMBER 30390772. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 A/R PINCH WELD EDGE COVER, BLACK -- NOT SHOWN 30302690. . . . . . . . . . . . . . . . . . . .

Appendix


Glossary of TermsThe following is a list with descriptions of some of theterms used in this manual (this includes the glossary ofterms found in the Safety Manual Appendix section):

AccumulatorA hydraulic device that stores fluid power energy in much the same way that a capacitor stores electrical energy. Because an accumulator will store energy, it MUST be drained and depressurized before work begins on an accumulator equipped actuator or hydraulic system.

AgitatorA device set in the concrete hopper to keep concrete moving, which prevents it from setting. It is typically a rotating shaft to which several paddles have been mounted. See Also: Hopper Grate

AWS D1.1The code for structural welding with steel as defined by the American Welding Society. Sections 3, 5, and paragraph 9.25 of Section 9 apply. See Also: Certified Welder and EN 287-1

Blanking PlateAlso known as a blanking plug or end cap. its purpose is to prevent material from falling out of the delivery system (typically the end hose) when moving a full boom over personnel or property.

BlockageSimply put, if the pump is pushing and concrete fails to come out at the point of discharge, it is called a blockage. The causes of blockages are detailed in Section 6 of this manual. In all cases, blockages can create a danger-ous situation by causing high concrete pressure, combined with the some-times uncoordinated efforts of untrained workmen to remedy the problem.

Bulk DensityThe mass of a substance per volume. For example, 1 cubic foot of air weighs much less than 1 cubic foot of water. 1 cubic foot of lightweight concrete

weighs less than 1 cubic foot of steel entrained concrete. We could say that steel entrained concrete has a higher bulk density than lightweight concrete. All calculations for the Operation Man-uals and specifications of concrete pumps are based upon 150 pounds per cubic foot, which is the approxi-mate mass of hard rock (normal) con-crete.

Certified OperatorAn operator that has been issued a certification card by the American Concrete Pumping Association. There are several classes of certification, each relating to a different category of pump. For an operator to become cer-tified, he (she) must pass the tests given regarding operation, set up, and clean-out for each category of pump, plus pass the safety rules test which is common to all certification categories, plus meet the experience require-ments set forth for each category, plus maintain a safe and clean driving record. Certified operators are consid-ered qualified operators (in regards to their categories). See Also: Expert, Qualified Operator

Certified WelderAs it relates to concrete pumping and this Safety Manual, a Certified Welder is a person that has applied for, taken and passed the American Welding Society (AWS) or the European Nor-mal (EN) test for structural steel weld-ing. Anyone welding on a concrete pump placing boom, outriggers, tow-ers, etc. must be certified to AWS D1.1 Sections 3, 5, and paragraph 9.25 of Section 9 AND/OR EN287-1/PREN288-3.

Concrete PressureThe force per square area that is exerted on the concrete. The concrete pressure will always be a ratio in direct proportion to the hydraulic oil pressure on the concrete pump circuit. See also: Maximum Pressure

Appendix


ConductorsMaterials that will conduct electricity. Copper, silver, aluminum, gold, steel, and water are considered GOOD con-ductors of electricity. Air, fiberglass, rubber, ceramics and glass are consid-ered POOR conductors. All of these conductors have a resistance to the flow of electricity that can be mea-sured in terms of ohms per linear foot. As voltage gets higher, more current flows through the same resistance. In the case of high voltage electric wires (8000 volts, for example) even the poor conductors will carry enough current through your body to ground that you could be killed (as little as 35 milliamps will cause cardiac arrest). Some con-ductors, like air, resist electricity very well, but if the voltage gets high enough, current will flow (lightning is a good example of this). See Also: Elec-trocution

DecibelsOne tenth of a bel. Abbreviated dB. It is a measurement of volume. As it applies to concrete pumps, it is a mea-surement of the sound pressure level one meter away from a noise source. Because constant exposure to loud sound can cause permanent hearing loss, O.S.H.A. has developed guide-lines for time limits on exposure to sound at different volume levels. The chart can be found in Section 6 of this manual.

Drive EngineThe primary source of power for a hydraulic system. Typically, the word “engine” denotes an internal combus-tion device, where as the word “motor” denotes an electrical device. See also: Prime Mover

ElectrocutionMade from the words “Electric” + “Exe-cution”. It means death by electricity. See also: Conductors

EN 287-1 / PREN 288-3The code for structural welding with steel as defined by the European Norm. See also: Certified Welder

ExpertAs used in this Safety Manual, an expert is defined as: persons that, on the basis of their specialized training and experience, have developed a high degree of knowledge and skill in the areas of concrete pumps, concrete pumping, clean-out procedures, gen-erally accepted engineering norms, and safety regulations to the point that they are able to evaluate equipment and processes as they relate to job safety. They would demonstrate their knowledge and abilities by passing the certification testing and experience requirements of the American Con-crete Pumping Association. Other experts may include master mechan-ics and after-sales service technicians of the manufacturer. See Also: Certified Operator

Foreign MaterialMaterial that was never intended to be pumped, which ends up in the con-crete hopper. Examples of foreign material include small animals, ham-mers, ready mix truck fins, unmixed clumps of cement, hardened concrete that breaks away from ready mix truck fins, soda pop cans, etc. Many of these items can create a blockage if pumped.

Go DevilA plug made from a rubber composite, usually with several fins that expand to seal when pressure is applied. They are intended to be inserted in a steel delivery pipeline and pushed with water or compressed air for the pur-pose of cleaning the pipe. Not to be used with rubber hose or short sec-tions of pipe. See Also: Sponge Ball

GuideAn assistant brought in to help in back-ing up a truck or trailer, or other cir-cumstances where the driver cannot

Appendix


see enough to assure safety. See also: Spotter

High VoltageFor the purposes of this manual, any-thing over 120 volts AC will be consid-ered high voltage. In the U.S., electrically driven concrete pumps nor-mally operate the motors at 480 volts AC (high voltage) and the controls at 24 volt DC (low voltage). When dealing with electric wires in residential or industrial areas the voltage will be approx. 8000 volts to ground, or 13,800 volts from phase to phase (dis-tribution voltage). When dealing with electric wires that are mounted on steel towers, high above the ground, the voltage will range from 100,000 to 1,000,000 volts (transmission voltage).

Hopper GrateA meshwork placed over the concrete hopper, typically made from steel bars. It serves the functions of keeping human body parts away from the agi-tator (when left in its proper position), and keeping large foreign objects from falling into the hopper, which could cause blockages if they were pumped. The hopper grate MUST be secured into position to be effective.

Jacking the OutriggersAdjustment of the outriggers in the ver-tical direction. With boom mounted concrete pumps you should strive to make the adjustments so that the unit sits within 3° of level.

Licensed ElectricianA qualified electrician licensed by the state, county or municipality where the connections are to be made. In some locations electricians are not required to be licensed, and in these cases the work should still be carried out by com-petent professionals. Under no circum-stances should high voltage connections be made by a concrete pump operator or related personnel.

MaintenanceAll procedures for servicing, inspection and repair of concrete pumps and related equipment and devices. Main-tenance and inspection are methods of MAINTAINING the desired state of the equipment. Repair is the method of RESTORING the desired state of the equipment.

Maximum PressureWhen talking about a hydraulic sys-tem, maximum pressure refers to the highest pressure that can be achieved with the settings of the circuit relief valves. When discussing concrete out-put, maximum pressure refers to the pressure that will be developed if the hydraulic system pressure reaches the relief valve setting. Concrete pressure is always the force at which the differ-ential cylinders are moving, divided by the cross sectional area of the con-crete cylinder. Maximum concrete pressure, then, is developed when the differential cylinders are moving with maximum force, which is determined by the hydraulic system relief valve setting. During normal pumping, the resistance of moving the concrete through the pipe or boom creates the pressure needed by the pump, and is well under the maximum pressure. See Also: Concrete Pressure

Minimum Safety DistanceIn this manual, the term “minimum safety distance” refers to the closest distance that you are allowed to approach an object, electrical wires, etc. and still leave room for errors in human judgement or machine mal-function. With electrical wires in the U.S., this distance is 17 feet, as rec-ommended by the American Concrete Pumping Association. This distance may have other values in different countries.

Murphy’s LawAn old saying that goes like this: “Any-thing that can go wrong, will go wrong, and at the worst possible moment”.

Appendix


Operational AreaThe area around a working piece of equipment or point of discharge where dangers can be encountered due to the nature of the machinery or process in use. Do not allow unauthorized presence in this area for safety rea-sons.

O.S.H.A.Occupational Safety and Health Administration. A branch of the United States federal government that deals with job safety. They establish and enforce safety regulations for industry and business. Among the areas over which they have authority are con-struction job sites and work shops.

Personal Protective ApparelThings you can wear to protect your-self from potential dangers in a con-crete placing environment. Examples are:

• Snug fitting work clothes• Steel Toed work boots• Lime resistant gloves• Safety glasses• Ear muffs or ear plugs• Rubber boots when you have to

stand in concrete• Hard hat

Point of DischargeThe location of concrete expulsion from a delivery system. This can be the point of placement (the actual form that is being filled with concrete) or the clean-out area after completion of the job.

PourUsed by the concrete pumping indus-try and in this manual as a noun. It is the specific job for the pump during any given time period. E.g. “We’ll grab lunch right after the pour”.

Prime MoverThe primary power source for a hydraulic system. The term “prime mover” is generic in that is denotes neither an internal combustion engine nor an electric motor.

PTOPower Take Off. A switchable output from the transmission or an intermedi-ate gearcase. On a concrete pump it is used to divert the power from the engine and drive train to turn the hydraulic pumps.

Qualified OperatorAn individual that has:

• reached the age of 18 years, and• is physically and mentally capable,

and• has been trained in the proper

operation and maintenance of the pump and placing boom (if appli-cable), and

• has demonstrated their capabili-ties to their company in respect to the operation and maintenance of the pump and placing boom, and

• can be expected to perform these duties, as assigned, in a reliable manner.

Qualified PersonnelA generic term used to describe a per-son that is qualified in the area of application. For example, having your boom repairs inspected by “qualified personnel” before use would refer to inspection by a certified welder or cer-tified welding inspector. Having repairs to your hydraulic system done by “qualified personnel” would refer to repairs made by qualified workshop personnel.

Qualified Workshop PersonnelAn individual that:

• has reached the age of 18 years, and

• is physically and mentally capable, and

• has been trained in proper repair, maintenance, and inspection pro-cedures plus the pertinent safety rules for concrete pumps and related equipment, and

• has demonstrated their capabili-ties to their company in regards to the above mentioned procedures and rules, and

• can be expected to perform these

Appendix


duties, as assigned, in a reliable manner.

Rock JamA specific type of blockage caused when the cement and fines of the con-crete are not present in sufficient quantity to fully coat the larger aggre-gates and the walls of the delivery sys-tem. In these cases, the rock (larger aggregates of the mix) will form a wedge inside of the pipe. Resistance to movement then becomes overpow-ering and the concrete stops. Increas-ing pressure to try to remove the wedge only results in forcing more of the finest particles past the rocks, compounding the problem. In some cases the wedge can be broken up by alternately pumping in forward and then reverse. See also: Blockage

Separate PipelineA pipeline that is laid between the con-crete pump and the point of discharge, other than the placing boom pipeline.

Shut-Off ValveIn hydraulics: a valve with the ability to stop the flow or pressure of hydraulic oil. Must be able to withstand the max-imum pressure of the hydraulic circuit that it controls. In concrete: A manually or hydraulically operated valve that will prevent the flow of concrete in either direction. Some concrete shut-off valves also have the ability to divert the flow of concrete to a different pipe-line, for example, to a discharge point for clean-out. The shut-off valve must be able to withstand the maximum pressure on the concrete of which the pump is capable.

Soil PressureThe force per square area that is exerted on the ground by the outrigger legs. The amount of pressure that the soil will support varies with the compo-sition and compaction of the soil. To make a determination on the stability of the soil, see the chart in Section 5 of this manual.

Sponge BallA medium to hard sponge formed into a sphere and used to clean the inside of delivery pipelines. See Also: Go Devil

SpotterA spotter is a person that stands at a vantage point where he (she) can see both the point of discharge and the operator of the pump. The spotter would then direct the operator to oper-ate the unit as required by the job cir-cumstances with 2 way radios or hand signals. A spotter can be anyone that is familiar with the safety rules for the pump and workers, and is equipped with a radio or knows the appropriate hand signals. A spotter is needed whenever the operator cannot safely see the point of placement or the dis-tance between the unit and an unsafe area. See Also: Guide

Sucking BackThe act of putting the concrete pump into the reverse mode for any of sev-eral reasons. Some examples of rea-sons to suck back:

• To relieve pressure in the delivery system before opening when a blockage has occurred.

• To clean the boom with a sponge ball upon completion of the pour.

• To remove concrete from the boom for the purpose of folding the boom for moving.

Thrust BlockAlso known as a “dead man”. This is a large block of poured concrete, usually with one or more sweep elbows cast inside, placed at the bottom of a verti-cal run for the purpose of supporting the weight of the vertical run, and lat-eral stabilization of the pipeline. It sta-bilizes and supports the vertical run by virtue of its enormous mass (normally one cubic yard or larger).

Towing VehicleIn this manual, “Towing Vehicle” applies only to trailer mounted con-crete pumps. It is the vehicle that you will use to tow the trailer on the road,

Appendix


job site, or in the yard. Size and condi-tion of the towing vehicle is extremely important in these applications. See the safety rules regarding this subject in Section 4 of the Safety section.

Transport PositionThis relates to the position of the boom. Boom is completely folded and lowered into the rests. For traveling, the boom straps must be secured. When stowing in the traveling position because of a thunderstorm, for exam-ple, but no travel is imminent, the boom straps need not be secured.

UnauthorizedWithout authority, without permission. Examples: Unauthorized operation of the boom could be operation by a passing teenager, unauthorized repairs to the boom could be repairs made without the manufacturers per-mission.

Unintentional MovementMovement of the pump, boom or related equipment without a specific intentional command by the operator. An example of an unintentional move-ment would be if an operator fell while walking with the remote control box and accidentally hit a joystick, which caused a boom movement. Uninten-tional movement can be avoided by disabling the hydraulic system with the emergency stop devices when not in immediate use.

Vertical RunSections of concrete delivery pipeline that are running in an up (or down) direction. Vertical runs have very spe-cific procedures and rules for installa-tion, support, cleaning, and inspection. Concrete pumping personnel should, therefore, have specific training in these procedures and rules before attempting to use them in a job setting.

Water JetThe actual stream of water that comes out of the end of a water hose or pres-sure washer. This is the only part of

the water system that needs to go into the hopper, concrete valve, or water-box for cleaning.

Additional Reading MaterialThis is a partial listing of the books that have beenwritten on the subject of concrete pumping. Books thatwere omitted were done so unintentionally.

• “Pumping Concrete and Concrete Pumps” byKarl Ernst v. Eckardstein, published by F. W.Schwing GmbH

• “Pumping Concrete - Techniques andApplications” by Robert Allen Crepas,published by the Aberdeen Group

• “Nomographs - A guide to usage” by RobertEdwards, © 1992, Schwing America, Inc.

Appendix


List of Lubricants and NitrogenThis list describes the materials that were installed inyour concrete pump unit when it left the factory. Otherbrands of lubricants and their usage are described inthe following lists.

Hydraulic oil

Gearcase oil

Truck fluid levels

Compressor oil

Grease for gears and spline couplers

Grease for autogreaser

Dry nitrogen

Texaco Rando 46

Mobilube® HD 80w-90

See owners manual for your specific truck

Mobil Rarus 427 or 429

Castrol Industrial-Optimoly Paste White

Mobil Grease HP or CM-S

Any brand of dry nitrogen is suitable forrecharging accumulators

Materials.eps

Appendix


Hydraulic OilsISO viscosity VG 32 = winter in northern US and CanadaISO viscosity VG 46 = summer in northern US and CanadaISO viscosity VG 68 = Tropical areas, desert summers, indoor uses.

• The following table shows the characteristics of Rando HD 46. You may use this information for comparison with other brands.

• Some oil manufacturers offer vegetable based hydraulic oils which are considered environmentally friendly (the additive packages are not inert, however). These vegetable-based oils must NEVER be mixed with mineral based oils. A complete flush of the hydraulic system must be performed when changing to this type of fluid. See the list below for a sample of the available oils and viscosities.

OM14

Brand

Texaco Rando HD* Texaco Rando HDZ**Mobil DTEShell TellusAral VitamBP - EnergolEsso - NutoTotal - Azolla

VG 32 / HLP HD 32

HDZ 32 DTE 24

32GF 32

HLP 32H 32 ZS 32 HS 32

Viscosity / DIN quality designation VG 46 / HLP

HD 46HDZ 46DTE 25

46GF 46

HLP 46 H 46 ZS 46 HS 46

VG 68 / HLP HD 68

HDZ 68 DTE 26

68GF 68

HLP 68 H 68 ZS 68 HS 68 Wintershall - Wiolan

* Rando HD 46 is installed in new machines at the Schwing Factory - standard** Rando HDZ is available for installation in new machines from the Schwing Factory - optional

BrandTexaco Biostar Hydraulic 32 Texaco Biostar Hydraulic 46Mobil EAL 224-HShell Naturelle HF-M

Vegetable Based Hydraulic OilsViscosity Information

Considered equivalent to ISO VG 32 viscosityConsidered equivalent to ISO VG 46 viscosityConsidered equivalent to ISO VG 36 viscosityConsidered equivalent to ISO VG 42 viscosity

ISO Viscosity

Class

Viscosity cST @ 40 C

Viscosity cST @ 100 C

Viscosity Index

GravityAPI

Flash point

F

Pour point

F

Foam, Seq IIml foam @ 0/10

minutes

VG 32 30.1 5.3 106 30.7 385 -25 20/0

VG 46 46.2 6.9 105 29.3 425 -20 20/0

VG 68 65.5 8.7 103 28.6 445 -20 20/0

Appendix


Gearcase Oils

Compressor Oils

A) for distribution gearcases

B) for motor vehicle gearcases

• The order of the list is meaningless. Any oil that meets the DIN quality designation and ISO viscosity specification may be used.

• The lubricants listed above are suitable for continuous ambient temperatures of -10 C (14 F) to +40 C (104 F). For conditions outside of this range, contact the oil manufacturer for recommendations.

• Viscosity class 220 roughly corresponds to SAE 90.

• Use VG 100 oil when ambient temperature is 0 to 10 C (32 to 50 F).

• Use VG 150 oil when ambient temperature is above 10 C (50 F).

Brand

TexacoMobilShellAralBPEssoWintershall

Viscosity / DIN quality designation VG 220 / CLP

Meropa 220Mobilgear 630Omala Oil 220

Degol BG 220, Degol BMB 220Energol GR-XP 220

Spartan - EP 220Wiolan - IT 220

Brand

TexacoMobilShellAralBPEssoWintershall

Viscosity / Mil-L quality designation 90 (85w-90) / 2105 B

Geartex EP-CMobilube HD

Spirax HD, Spirax MBGearbox Oil HYP

Energear Hypo 90, Hypogear 90 EPGear Oil GX-D, Gear Oil GX

Wiolan Hypoid Gearbox Oil 90

Brand

TexacoMobilShellAralBPWintershall

ISO Viscosity / DIN quality designation VG 100 / VDL

Compressor Oil - EP 100Rarus 427

Corena - H 100Motanol - HE 100Energol - RC 100Wiolan - CD 100

VG 150 / VDLCompressor Oil - EP 150

Rarus 429Corena - H 150

Motanol - HE 150Energol - RC 150Wiolan - CD 150

OM

15

Appendix


Grease

A) For filling the automatic greasers

B) For all other bearings

• The order of the lists is meaningless. Any grease that meets the quality designation and viscosity specification may be used.

• Shell Alvania is installed in new machines at the Schwing factory.

• Any equivalent grease may be used.

OM19A

Brand

TexacoMobilShell

Viscosity / DIN quality designation EP 2 / CLP Starplex 2

Mobilgrease HPAlvania EP - 2

Brand

Texaco

ShellAralBPEssoOptimal

Viscosity / Pressure rating 2 / EP

Multifak EP-2Mobil Mobilith AW 2

Alvania grease R 2HLP 2

Energrease LS2Multipurpose grease Beacon 2

Olitsta longtime 3 EP

Appendix


Hydraulic Schematics

HBV 160/260

07/14/05

GVOLUME

S1

35 psi2.4 bar

30 psi2 bar

M

COOLER

SAFETY

CONTROLKNOB

S2

A B

P T

NG6

1.7mm 1.7mm

3867 psi267 bar

RELIEF

PUMPON / OFF

300 bar

10u FILTER

12.35mm

HBV 160 / 260

0.7mm

1450 psi100 bar

A

P

HBV160 only

3

Appendix


Hydraulic Schematics - continued - BPA 450

50/41/70054

AP

B

Appendix



50/41/70005

AP

B

Appendix



40 /03/90

R02 -D

H0002

AP

B

Appendix


Electric Schematics

BPA 450/500

Appendix


WP FWD/REV w/FWD VIBRATOR

05/15/05

WPFWD/REVw/FWDVIBRATOR

Appendix


Electric Schematics BPA 2000

01/0

1/00

2000

BP

A

WH

ITE

YE

LLO

W

OR

AN

GE

OR

AN

GE

E-S

TO

PE

-ST

OP

12

WH

ITE

WH

ITE

WH

T

YELLOW

WHT/BLKWHT/BLK

GREEN

PURPLE

BLUE

ORANGE

OIL

F410 9

37

PU

MP

AG

ITAT

OR

DU

MM

YP

LUG

RE

MO

TE

MU

ST

BE

PLU

GG

ED

IN

FO

RP

UM

PT

OO

PE

RAT

E

T

RED

RED

6A

ALT

BLACK/WHITE

0

12

330 0,

1

WHITE

GREY

65

B+

D+

ALT

ER

NA

TOR

4

GR

EE

N

ORANGE

1719

W

1550

a

30

11

M

K3

OF

FO

N

F2

BLACK

WHITE/ORANGE

TAC

HO

ME

TE

R

853087

a8786

ON

,OF

F

GG+

H

E-S

TO

P

WH

ITE

F3

20A

GR

ATE

SA

FE

TY

SW

ITC

H

TAIL

RIG

HT

LEF

T

BLACK

12GWHITE

50a

3012

STA

RT

ER

31

12V --+

FAN

FU

EL

GR

EE

N31

D--

P

K1

LO

R

BROWN

YELLOW

WHITE

GREEN

853087

a8786

SH

UT

OF

F

ON

/OF

F

BY

PAS

S

10A

10A

853087

a87

86

K2

8

58 3158 M

SLO

WB

LOW

WHITEWHITE

YELLOW

VIB

RAT

OR

BO

SC

H

ST

RO

KE

CO

UN

TE

R

13

26

PR

OX

IMIT

YS

WIT

CH

10A

BLUE

BLACK

BROWN

OF

FO

N

ON

,OF

F

TAIL

LIG

HT

S

K4

86

3087a87

85

30A

DU

MM

Y

WH

ITE

/GR

EE

N

GR

EE

N

CA

BLE

RE

MO

TE

CO

NT

RO

L

E-S

TO

PO

NO

FF

ON

,OF

F

BA

CD

FE

BA

CD

FE

BA

CD

FE

B

BA

DF

CD

EA

F

E

OM

NE

XW

IRE

LES

SR

EM

OT

EC

ON

TR

OL

OP

TIO

NA

L

FU

NC

TIO

NS

E--S

TO

PF

WD

RE

V--

+

PLU

G

F1

10A

Appendix


Electric Schematics WPT 50/70/95

1

Y1

2K

9

K10

K12

K11

Y5

Y4

Y7

Y6

PU

MP

FO

RW

AR

DP

UM

PR

EV

ER

SE

EN

GIN

ES

PE

ED

K5

K4

K2

K1

86 8530

8787

a

86 8530

8787

a86 85

30

8787

a86 85

30

8787

a86 85

308787

a

K7

K8

K6

86 8530

8787

a

86 8530

8787

a

86 853087

87a

86 8530

8787

a

EL

EC

. ST

RO

KE

LIM

ITE

R M

OD

UL

E

EL

EC

. ST

RO

KE

LIM

ITE

R

1 2

Y3

BA DC

2 1

Y2

2 1

2 1

2 1

+POWER+COIL-COIL

PWR. COMSIG COM

CURVOLTREF

F8 7

.5A

Hor

n

SA

FE

TY

RE

LA

Y

A1

T11

T12

T12

T22

1323

3341

T33

T34

X1

X2

1424

3442

A2

2 1

2 1

Y9

Y10

CP

DU

MP

VALV

E

HO

PP

ER

GR

AT

E

SW

ITC

H

13 14

F7 7

.5A

Trac

king

: y:p

aulk

at\is

odoc

\200

291.

ai

WP

T 5

0/70

/95

Pag

e 1

of 2

Rel

ease

Initi

als

AK

SA

IE 2

00xx

-1/2

CH

AN

GE

X1

C2

C3

A4

C1

B3

A3

A5

B5

B1

C4

A2

A1

B2

1 2

1 - R

emot

e ca

ble

box

2 - M

ain

cont

rol b

ox

1 2

ST

OP

Em

erg.

STO

P

R2

10 K

R1

2 K

Ele

c. S

tro

keL

imit

er

K3

86 8530

87a

87

Lam

p

C5

C2

C3

A4

C1

B4

B3

A3

A5

B5

B1

C4

A2

A1

B2

C5S

TO

P

1K

R

esi

stor

1/4

watt

E-S

TOP

RE

V. x

xxxx

x

EL

EC

TR

ICH

OR

N

Agi

tato

r

2

13

Con

cret

e P

ump

O

2

13

U,D

+_

Eng

ine

Thro

ttle

Off,

On

2

13

Vib

rato

r

1918

78

15

E F G H I KJ L M N O

A

CC

UM

DU

MP

VALV

E

D1

D2

D3

D4

D5

AG

ITA

TOR

1 2

1 2

2

13

1314

910

1112

White/Black

Bla

ck/W

hite

Yello

w

YellowYellow

Red

Red

Red

Red/Wh

Red/Wh

Black

Black

Bla

ck

Bla

ck

Bla

ck

Bla

ck

Bla

ck

Black

Purple

Pur

ple

Red

/Whi

teB

lue/

Whi

te

Red

Green

GreenGreen

Gre

en

Whi

te/G

reen

Whi

te

Red

/Whi

te

Whi

teW

hite

Yello

w

Whi

te

Ora

nge

Bla

ck/W

hite

Whi

te/G

reen

Whi

te/B

lack

Whi

te/G

reen

Whi

te/R

ed

Black/White

Bro

wn

Blue

White/Black

White/Red

Appendix


Electric Schematics WPT 50/70/95 - continued

Off,

On

2

13

Vib

rato

r

Agi

tato

r

B2

+

F415

A

K14

D6

D7

K15

F3 15A

K13

CO

NT

INU

OU

SD

UT

YS

OL

EN

OID

&M

AIN

FU

SE

EL

EC

TR

ICV

IBR

AT

OR

TAC

HO

ME

TE

RS

EN

DIN

GU

NIT

PT

OS

WIT

CH

OIL

CO

OL

ER

G

86 853087

86 853087

F5 25A

F2 15A

F1 10A

8586

3087

1 2

13

64

25

R, L

O

2

13

2

13

Off,

On

2

13

+

G

+

1 21 2

BA D E FC G H I KJ L M

R34

R2

10 K

2 K

+_

ST

OP

ST

OP

ST

OP

Loca

lR

emot

e

Eng

ine

Thro

ttle

Con

cret

eP

ump

Hou

rM

eter

Tach

Hor

nO

il C

oole

rE

lec.

Str

oke

Lim

iter

(opt

.)La

mp

ST

OP

E-S

TOP

N O

Trac

king

: y:p

aulk

at\is

odoc

\200

292.

aiIn

itails

AK

SA

IE 2

0xxx

-2/2

CH

AN

GE

G1

M2

S9

K16

F6,

80A

M

M1

M

-+

WP

T 5

0/70

/95

P

age

2 of

2 Rel

ease

RE

V. x

xxxx

x

R,O

,F

R

,O,F

2

13

1617

12

35

46

2021

1K

R

esi

stor

1/4

watt

Purple

White/Black

Blue/White

Bla

ck/W

hite

All

grou

nds

gree

n

Red

Ora

nge

White/Orange

White/OrangeWhite/Orange

White

White

White

White

White

Black

Bla

ck

Bla

ck

Black

BlackBlack

Grey

Red/White

White/Red

Bla

ck

Bla

ck

Bla

ck

Pur

ple

Red

/Whi

teB

lue/

Whi

te

Red

Whi

teYe

llow

Yellow

Whi

te

Whi

te

White

Ora

nge

Bla

ck/W

hite

Whi

te/B

lack

Whi

te/G

reen

White/Green

White/Green

Whi

te/R

ed

Appendix


Electric Schematic SP 1000X

BLACK

YELLOW

ORANGE

ORANGE

EèSTOP

EèSTOP

WHITE

WHITE

F1

CABLEREMOTECONTROL

EèSTOP

FWD

ON,OFF,ON

ALT

BLACK/WHITE

0

12

330 0,1

17

19

15

50a

30

EèSTOP

GRATE

BLACK

K1

LOR

F3

10A

ENGINE

COOLANT

LEVEL

10A

85

3087a

87

86

K3

M

SLOW

WHITEWHITE

YELLOW

STROKE

COUNTER

VIBRATOR

BROWN

NREV

RED

FNR

K2

85

30

87a

87

86

OFFON

ON,OFF

B+

D+

ALTERNATOR

W50a

30

STARTER

31

12V

-+

31

D-

K6

86

30

87a87

85

85

30

87a

87

86

B

BA

DF

CD

EA

F

E

OPTIONALWIRELESSREMOTECONTROL

FUNCTIONS

E-STOP

FWD

REV

-+

DUMMYPLUG

GREEN

BA

CD

FE

BA

CD

FE

BA

CD

FE

TAIL

RIGHT

LEFT

BROWN

RED

WHITE

GREEN

BLUE

BREAK

AWAY

BRAKES

-+

SWITCH

ELECTRICBRAKES

25A

G

GH

H

DN

UP

+

THROTTLE

O-

GH

GH

+0-

BLOW

7èPINRVCONNECTOR

F5

25A

F6

10ADRB13

DRB14

WHITE

WHITE

21

3

21

3

21

3

FNR 2

13 DRB32

DRB33

THROTTLE

AGITATOR

DRB36

DRB31

DRB15

12

DRB12 K78

DRB6 K56

WHITE/BLACK

WHITE/RED

WHT/BLK

RED/WHITE

BLACK/WHITE

K77

AIR

FILTER

SWITCH

WHITEWHITE/RED

WHITE

DRB41

DRB11

K79DRB42

BROWN

DRB29

DRB34

+ -

100

OHM

2W

DRB18

DRB35

DRB30

PRE

+-100

OHM

2W

HEAT

DRB4

DRB40 K92

K29

+-100

OHM

2W

COOLANT

DRB9 K70

+-100

OHM

2W

DIAG.

DRB5 K55

DRB19

DRB16

DRB24

30A

DRB28

DRB44

DRB43

K2

K4

K6

DRB26

DRB27

F4

10A

F2

30A

DRB17

2 3

WHITE

DIAGNOSTICPLUG

AB

MK

GH

FDISPLAY

85

30

87a

87

86

DRB21

DRB23

DRB25

K1

K3

K5

DRB10K72

WHITE

WHITE

WHITE

GREEN WHITE

WHITE

POWER

RELAY

75A

120

OHM

+-

CANL

CANH

2178

K61 DRB39

K62 DRB38

K82 DRB8

K60 DRB7

K25 DRB2

NON-SHIELDED

TWISTED

PAIR

*

*

*

BLACK

BLACK

BLACK

WHITE

WHITE

WHITE

K28

BLACK

GREEN

WHITE/ORANGE

BLUE

BLUE/WHITE

WHITE/YELLOW

GREEN

GREEN

BLUE

GREEN

GREEN

BLACK

RED

RED

YELLOW

BLACK

K1

CONNECTOR

12

SAFETY

SWITCH

DUMMYPLUG

REMOTEMUST

BEPLUGGEDIN

FORPUMPTO

OPERATE

Appendix


Electric Schematics SP 1000 X - continued (ECM wiring diagram)

K1 DRB21WHITE

K3 DRB23WHITE

K5 DRB25WHITE

K15 DRB1

K25 DRB2BLACK

K29 DRB4BLUE

K55 DRB5WHITE/YELLOW

K56 DRB6WHITE/RED

K60 DRB7BLACK

K61 DRB38BLACK

K62 DRB39WHITE

K70 DRB9WHITE/ORANGE

K72 DRB10GREEN

K78 DRB12WHITE/BLACK

K79 COOLANT SENSORBLACK

K82 DRB8WHITE

K92 DRB40BLUE/WHITE

K28

K63RED

K64GREEN

K77WHITE

ORANGEEMERGENCY STOPS

A

B

AIR FILTER SWITCH

FUELFILTER

CONNECTOR

ECMCONNECTOR

CONTROL BOXCONNECTOR

NON--SHIELDEDTWISTEDPAIRS

GREEN

K2

K4GREEN

K6

GREEN

GREEN

NEGATIVE12V

BATTERY

Appendix


Nomographs

SP 450

SP

450

P in P

SI

Q in yd3/hr.

20001800

16001400

1200600

400200

120

100

80

37

6020 40

1000800

1100

Technical identification number (T

K)

1479M

etric to English Conversion factor is TK x 18.966

Pow

er:

Model:

By:

Num

ber:M

ax Q

Revision date:

Power:

Model:Number: Max Q

Revision date:

SP

450

51

Kw

08

7

DM

12

13

07

150 l/m

80/50 x 1000:150P

umpkit M

odel:

SP 450

51 Kw087

121307150 l/m

Pipeline diam

eter in inches

Proportional value of pipeline in feet

For vertical placing,

add 1.105 PS

I per footof level difference.

Slum

p of fresh concrete in inches

(28,050)

51 Kw

100

2000

200

300

400

500

600

8001000

12001500

18002500

3000

2"

2.5"3"4"

5"6"

6"5"

4.5"4"

3" *

*estimate

Appendix


Nomographs - continued - SP 500

Model:

Num

ber:M

ax Q

Pum

pkit Model:

O.C

.

Pow

er:R

evision date:

By:

Model:Number: Max Q

Pumpkit Model: O.C.

Power:Revision date:

By:S

P 500

08

8190 l/m

80/50 x 1000:150N

A

1 x

54

Kw

DM

SP 500088 190 l/m

80/50 x 1000:150 NA

1 x 54 Kw

DM

SP

500

P in P

SI

Q in yd3/hr.

20001800

16001400

1200600

400200

120

100

80

45

6020 40

1000800

1100


K)

Metric to English Conversion

factor is TK x 18.966P

ipeline diameter in inches

Proportionalvalue of pipeline in feet

For

vertical placing,add 1.105 P

SI per foot

of level difference.

Slum


100

2000

200

300

400

500

600

8001000

12001500

18002500

3000

2"

2.5"3"4"

5"6"

6"5"

4.5"4"

3" *

*estimate

07

13

05

121307

TK 1566(29700)

54 Kw

Appendix


Nomographs - continued - SP 750 - 15

SP

750-15

P in P

SI

Q in yd3/hr.

20001800

16001400

1200600

400200

120

100

80

506020 40

1000800

1100


K)


factor is TK x 18.966

Pow

er:

Model:

By:

Num

ber:M

ax Q

Revision date:

Power:

Model:Number: Max Q

Revision date:

SP

750-15

75

Kw

08

9D

M1

21

30

7204 l/m

80/50 x 1000:150P

umpkit M

odel:

SP 750-15

75 Kw089

121307204 l/m

Pipeline diam

eter in inches


For


SI per foot


Slum


75 Kw

100

2000

200

300

400

500

600

8001000

12001500

18002500

3000

2"

2.5"3"4"

5"6"

6"5"

4.5"4"

3" *

*estimate

TK 1875(35561)

Appendix


Nomographs - continued - SP 750 -18

WP

750-18X

P in P

SI

Q in yd3/hr.

20001800

16001400

1200600

400200

120

100

8070

6020 40

1000800

1100


K)

Metric to English Conversion factor is TK x 18.966

Pow

er:

Model:

By:

Num

ber:M

ax Q

Revision date:

Power:

Model:Number: Max Q

Revision date:

SP

750-1875

Kw

09

0D

M1

21

30

7237 l/m

90/50 x 1000:180P

umpkit M

odel:

SP 750-18

75 Kw090

121307237 l/m

Pipeline diam

eter in inches



add 1.105 PS


Slum


75 Kw

100

2000

200

300

400

500

600

8001000

12001500

18002500

3000

2"

2.5"3"4"

5"6"

6"5"

4.5"4"

3" *

*estimate

TK 1875(35561)

Appendix


Nomographs - continued - SP 1000 - 18

SP

1000X

P in P

SI

Q in yd3/hr.

20001800

16001400

1200600

400200

120

100

8070

6020 40

1000800

1100


K)


factor is TK x 18.966

Pow

er:

Model:

By:

Num

ber:M

ax Q

Revision date:

Power:

Model:Number: Max Q

Revision date:

SP

1000X0

91

DM

246 l/m

90/50 x 1000:180P

umpkit M

odel:

SP 1000X091 246 l/m

Pipeline diam

eter in inches


For


SI per foot


Slum


100

2000

200

300

400

500

600

8001000

12001500

18002500

3000

2"

2.5"3"4"

5"6"

6"5"

4.5"4"

3" *

*estimate 1

00

Kw

12

13

07

100 Kw071305

TK 2475(46941)

100 Kw

Appendix


Nomographs - continued - WPT 95

WP

1250X

P in P

SI

Q in yd3/hr.

20001800

16001400

1200600

400200

120

100

80

95.5

6020 40

1000800

942.5


K)

2800

Metric to English Conversion factor is TK x 18.966

Pow

er:

Model:

By:

Num

ber:M

ax Q

Revision date:

Power:

Model:Number: Max Q

Revision date:

WP

1250X11

2 K

w0

47

DM

05

07

99

294 l/m

80/55 x 1400:180P

umpkit M

odel:

WP 1250X

112 Kw047

050799294 l/m

Pipeline diam

eter in inches



add 1.105 PS


Slum


(53,105)

112 Kw

100

2000

200

300

400

500

600

8001000

12001500

18002500

3000

2"

2.5"3"4"

5"6"

6"5"

4.5"4"

3" *

*estimate

nomo047.eps

Appendix


Nomographs - continued - BPA 2000

600

44

42

40

38

36

34

500

400

300

200

100

100

112125150

6" 5" 4.5"

4"

10

150

140

130

120

110

100

20

30

40

70

80

1020304050708090100140160180220

Pipeline diameter in mmTechnical identification number

Wor

king

pow

er in

KW

Proportional value of pipeline in meters

For verical placing,add 0.25 bar per meter


3300

132 KW

PS

Spread measure of fresh concrete in cm

4 "Slump

6 "Slump

By: RE

Product

Date: 4/30/91

BPA 2000 HDD - 20 R

118 KW

RS

P in Bar

Q in

m3

/hr.

K2

K3

9008 " Slump

700

10001100200030004000

46

48

800

120108

200

60

Hyd. Pumps:

90

50

60

Appendix


Output Charts

SP 450

SP

Appendix


Output Charts SP 500

TD2011L04

SP

Appendix


Output Charts SP 750 -15

S

Appendix


Output Charts SP 750 -18

S

Appendix



TCD2012C

S

Appendix



S

Appendix



TCD2012C

S

Appendix


Output Charts SP 1000XHP

TCD2012C

S

Appendix


Output Charts BPA 2000

Alphabetical Index

Operation Manual - Line pumps

ALPHABETICAL INDEX

swg99a001.eps

Alphabetical Index

Aaccessories

for drivingchecklist . . . . . . . . . . . . .99

for pumpingchecklist . . . . . . . . . . . . .98

supplied . . . . . . . . . . . . . .82vibrator . . . . . . . . . . . . . . 114

accidentstraffic . . . . . . . . . . . . . . 102

additional reading material list . . . . . . 185agitator won’t operate . . . . . . . . . 104alternator

indicator light . . . . . . . . . . . .73appendix . . . . . . . . . . . . . . . 152

additional reading material . . . . . . 185electric schematics . . . . . . . . . 196fitting/wrench sizes . . . . . . . . . 155glossary of terms . . . . . . . . . . 180hydraulic oil viscosity chart . . . . . . 152hydraulic schematics . . . . . . . . 190minimum pipe wall thickness chart . . . 172nomographs . . . . . . . . . . 163, 201

using the graph . . . . . . . . . 163nomographs for this unit . . . . . . . 201output chart . . . . . . . . . . . . 157output chart for this unit . . . . . . . 208recommended emergency hose kit . . . 154scheduled maintenance checklist . . . . 156torque specifications . . . . . . . . 153

attitudearriving on time . . . . . . . . . . .98

Bbacking up (driving) . . . . . . . . . . 102balance loads . . . . . . . . . . . . . 115blockages . . . . . . . . . . . . . . 115

reversing the pump . . . . . . . . . 115boom

pipelineminimum wall thickness . . . . . 172

Ccaution . . . . . . . . . . . . . . . .10changing lanes (driving) . . . . . . . . 102clamps

washing . . . . . . . . . . . . . 113

cleanout . . . . . . . . . . . . . . . 115cleaning the hopper and valve housing . . 116cleaning the rock valve and material cylinders 120cleaning the waterbox . . . . . . . . 122removing set material from hopper . . . 119

cold weather pumping . . . . . . . . 113, 124preheating the hydraulic oil . . . . . . 125time constraints . . . . . . . . . . . 113

concrete . . . . . . . . . . . . . . . 74from worn out mixers . . . . . . . . 111inspecting before dumping . . . . . . 111minimum hopper level . . . . . . . . 112time constraints . . . . . . . . . . . 113very cold weather . . . . . . . . . . 113

control system, hydraulic . . . . . . . . 29controls

concrete pump forward - reverse . . . . 74main control panel . . . . . . . . . 72

couplingscomparison . . . . . . . . . . . . 171grooved type . . . . . . . . . . . . 171heavy-duty type . . . . . . . . . . . 171male/female o-ring type . . . . . . . 171metric type . . . . . . . . . . . . 171victaulic type . . . . . . . . . . . . 171

cylinderdifferential . . . . . . . . . . . . . 31rock valve slewing . . . . . . . . . 30

Ddanger . . . . . . . . . . . . . . . . 10dead battery . . . . . . . . . . . . . . 104delays

and blockages . . . . . . . . . . . 114balance load . . . . . . . . . . 114, 115hot weather . . . . . . . . . . . . 114keeping the concrete alive . . . . . . . 114very cold weather . . . . . . . . . . 114

delivery systempipe

end comparison . . . . . . . . . 171diagram explanation

s valve . . . . . . . . . . . . . . 30diagrams

hydraulic control system . . . . . . . 29nomographs . . . . . . . . . . . . 201

Alphabetical Index

rod side-piston side pumping . . . . . 123differential cylinder

diagram explanation . . . . . . . . . 31driving

backing up . . . . . . . . . . . . 102changing lanes . . . . . . . . . . . 102license requirements . . . . . . . . . 102safety rules . . . . . . . . . . . . 102

see also, safety manual

Eelectric schematics . . . . . . . . . . . 196emergency

stopping procedure . . . . . . . . . 27emergency hose kit . . . . . . . . . . 154emergency procedures

disabling the entire machine . . . . . 114emergency stop switch . . . . . . . . . 90

hopper area . . . . . . . . . . . . 90operator’s panel . . . . . . . . . . 27

engine quite running . . . . . . . . . . 104engine running but pump won’t operate . . 104engine won’t start . . . . . . . . . . . 104equipment pre-checks

on pump . . . . . . . . . . . . . 101on truck . . . . . . . . . . . . . 101

Ffitting/wrench size chart . . . . . . . . . 155fuses . . . . . . . . . . . . . . . . 90

Gglossary of terms, alphabetical . . . . . . 180grease points

rock valve . . . . . . . . . . . . . 88greasing

agitator bearings . . . . . . . . . . 108list of lubricants . . . . . . . . . . 186rock valve . . . . . . . . . . . . . 108

guards . . . . . . . . . . . . . . . . 90

Hhopper

cleaning the hopper . . . . . . . . . 116removing set material . . . . . . . . 119spraying with form oil . . . . . . . . 108

how toreach us . . . . . . . . . . . . . . 11

hydraulic control system, diagram . . . . . 29hydraulic pumps

main . . . . . . . . . . . . . . . 28hydraulic schematics . . . . . . . . . . 190hydraulic system

pressure specifications . . . . . . . . 19

Iid tag . . . . . . . . . . . . . . . 12, 13id tag location . . . . . . . . . . . . . 12indicator light

alternator . . . . . . . . . . . . . 73oil pressure . . . . . . . . . . . . 73

Llaborers and oilers

safety rules . . . . . . . . . . . . 105license required to drive . . . . . . . . . 102list of lubricants and nitrogen . . . . . . . 186location

fuses . . . . . . . . . . . . . . . 72lubricate . . . . . . . . . . . . . . . 109lubricate . . . . . . . . . . . . . . . 109lubrication

quantity of slurry needed . . . . . . . 109slickline . . . . . . . . . . . . . . 109slurry

mixing . . . . . . . . . . . . . 109pumping it through . . . . . . . . 111

with commercial lubricant . . . . . . 109with portland cement . . . . . . . . . 109with ready mix grout . . . . . . . . . 109without slurry . . . . . . . . . . . 109

Mmaintenance . . . . . . . . . . . . . 127

preventive maintenancescheduled maintenance checklist . . 156

manufacturer’s statement . . . . . . . . 10missing id tag . . . . . . . . . . . . . 13

Nnew id tags . . . . . . . . . . . . . . 13nomographs

Alphabetical Index

explanation . . . . . . . . . . . . 163for this unit . . . . . . . . . . . . 201using the graph . . . . . . . . . . . 163

Ooil pressure

indicator light . . . . . . . . . . . .73oilers and laborers

safety rules . . . . . . . . . . . . 105output chart

checking your hydraulic pumps . . . . 159explanation . . . . . . . . . . . . 157for this unit . . . . . . . . . . . . 208

overviewagitator motor . . . . . . . . . . . .87fuses . . . . . . . . . . . . . . . .90main hydraulic pumps . . . . . . . . .28pressure relief valves . . . . . . . . .90rock valve components . . . . . . . .88rock valve slewing cylinder . . . . . . .30rod side-piston side configurations . . . 123safety devices . . . . . . . . . . . .90stroke limiter . . . . . . . . . . . .75vibrator (optional) . . . . . . . . . .89warning labels . . . . . . . . . . . .91waterbox . . . . . . . . . . . . . .80

Pparts, see spare partspersonal protective devices

breathing mask . . . . . . . . . . . 105list of . . . . . . . . . . . . . . 100

personal protective equipment, see personal protective devicespipe

weld on ends . . . . . . . . . . . 171pipeline (separate), see slicklinepiston side pumping

diagram . . . . . . . . . . . . . 123through the boom . . . . . . . . . . 123

placing crewsafety rules . . . . . . . . . . . . 105

pre-checksdanger of skipping . . . . . . . . . .98on pump . . . . . . . . . . . . . 101on truck . . . . . . . . . . . . . 101

preparation

for pumpingprechecks . . . . . . . . . . . 101rock valve . . . . . . . . . . . 105selecting a set-up location . . . . . 103spraying the hopper . . . . . . . . 108tools and accessories . . . . . . . 98

for travelafter cleanout . . . . . . . . . . 123

pressurespecifications . . . . . . . . . . . 19

Rreceptacle

remote control cable . . . . . . . . . 73remote control . . . . . . . . . . . . . 73

cable receptacle . . . . . . . . . . . 73rock valve

cleaning . . . . . . . . . . . . 116, 120component identification . . . . . . . 88preparation for concrete . . . . . . . 105slewing cylinders . . . . . . . . . . 30

rod side pumping diagram . . . . . . . . 123

Ss valve

diagram explanation . . . . . . . . . 30safety

alert symbol and signal words . . . . . 10arranging for a spotter . . . . . . . . 105blockages . . . . . . . . . . . . . 115devices . . . . . . . . . . . . . . 90

agitator shut-off . . . . . . . . . 90bypassing the dump valve . . . . . 114emergency stop switch . . . . . . 90fuses . . . . . . . . . . . . . 90pressure relief valves . . . . . . . 90warning labels . . . . . . . . . . 91

disabling the entire machine . . . . . . 114driving . . . . . . . . . . . . . . 102

backing up . . . . . . . . . . . 102changing lanes . . . . . . . . . . 102

minimum hopper level . . . . . . . . 112personal protective devices . . . . . . 100

breathing mask . . . . . . . . . 105rules for oilers and laborers . . . . . . 105rules for the placing crew . . . . . . . 105

schematics

Alphabetical Index

for this unit . . . . . . . . . . . . 190selection

of set-up location . . . . . . . . . . 103separately laid pipeline, see slicklineserial number

this unit . . . . . . . . . . . . . 11service

telephone numbers . . . . . . . . . 11service department . . . . . . . . . . . 11slickline

checklist . . . . . . . . . . . . . 98minimum wall thickness chart . . . . . 172washing . . . . . . . . . . . . . 113

slurryif it plugs . . . . . . . . . . . . . 111pumping it through . . . . . . . . . 111

spare partshours . . . . . . . . . . . . . . . 11telephone numbers . . . . . . . . 10, 22

special pumping situationscold weather pumping . . . . . . . . 124

specifications1200 pumpkit . . . . . . . . . . . 18900 pumpkit . . . . . . . . . . . . 18concrete pump . . . . . . . . . . 16, 18hydraulic pumps . . . . . . . . . . 18pressure of hydraulic circuits . . . . . 19pressure of pumpkit . . . . . . . . . 18torque . . . . . . . . . . . . . . 153

spotterarranging for . . . . . . . . . . . . 105

switchemergency stop . . . . . . . 27, 72, 90

Ttime constraints . . . . . . . . . . . . 113troubleshooting

checking your hydraulic pumps . . . . 159loss of boom and outriggers . . . . . . 114loss of electricity . . . . . . . . . . 114procedures . . . . . . . . . . . . 104time constraints . . . . . . . . . . 113

Vversion number

operation manual . . . . . . . . . . . iiivibrator . . . . . . . . . . . . . . . 89

Wwalk around

driver’s side . . . . . . . . . . . . 79hopper area . . . . . . . . . . . . 87towing end . . . . . . . . . . . . . 76

warning . . . . . . . . . . . . . . . 10warning labels . . . . . . . . . . . . . 91waterbox

cleaning . . . . . . . . . . . . . . 122filling with water . . . . . . . . . . 105keeping it full . . . . . . . . . . . 114safety . . . . . . . . . . . . . . . 80

Alphabetical Index

Documents

Schwing Sp 500 English